1. ABERTURA ACIONADA POR PAINPOINT

Are your iron ore processing margins being eroded by persistent operational bottlenecks? Plant managers and procurement specialists face significant challenges in primary crushing stages that directly impact the entire downstream circuit. Os pontos problemáticos comuns incluem:
Tempo de inatividade excessivo: Unplanned stoppages for liner changes and maintenance on underspecification crushers, custando centenas de horas de produção anualmente.
Altos custos de desgaste: Rapid abrasion of crushing components in the face of hard, abrasive magnetite or hematite ores, leading to unsustainable consumables expenditure.
Taxa de transferência inconsistente: Feed size fluctuations and material bridging causing chokefed or starved crushers, preventing consistent tonnage targets.
Regulatory Compliance Risk: Operating nonCE marked equipment exposes your project to legal liability, insurance complications, and potential site shutdowns in regulated markets.

How do you secure a robust primary crushing solution that ensures reliable throughput, controls operational costs, and meets stringent EU safety directives—all within a constrained capital budget?

2. VISÃO GERAL DO PRODUTO

Our solution is a CE Marked Stationary Primary Crushing Plant engineered specifically for hard rock iron ore applications. This turnkey module is designed for the initial size reduction of runofmine (ROM) iron ore to a consistent product for downstream conveying and processing.

Fluxo de Trabalho Operacional:
1. ROM ore is fed via dump truck or loader into a rugged vibrating grizzly feeder.
2. The feeder removes sub100mm fines via a grizzly section and evenly introduces oversize material to the primary jaw crusher.
3. The crusher reduces the ore to a nominal 150200mm product, which is discharged onto a main plant conveyor.

Escopo de aplicação: Ideal for greenfield installations or replacement of aging primary crushers in mediumtolarge scale iron ore operations processing magnetite, hematita, or goethite ores.

Limitações: This plant configuration is designed for primary crushing duty only. For full circuit needs, secondary/tertiary crushing and screening modules are required. Maximum feed size and capacity are bound by model specifications.

3. RECURSOS PRINCIPAIS

HeavyDuty Jaw Crusher | Base Técnica: Reinforced manganese steel jaws with optimized nip angle geometry | Benefício Operacional: Sustained high reduction ratios (tipicamente 6:1 para 8:1) on abrasive ore with minimal wear flat development | Impacto do ROI: Extended liner life reduces consumable costs by an estimated 1525% versus designs padrão.

Alimentador Grizzly Integrado | Base Técnica: Plataforma de aço de alta resistência com barras ajustáveis | Benefício Operacional: Prescreening increases effective crusher capacity by removing fines, reduces crusher cavity wear, and prevents plugging | Impacto do ROI: Improves overall plant throughput efficiency and protects the crusher from unnecessary abrasion.

Segurança certificada pela CE & Sistema de controle | Base Técnica: Full compliance with EU Machinery Directive 2006/42/EC, featuring guarded drive units, emergency stop circuits, and lockout/tagout points | Benefício Operacional: Provides a verifiable safety framework, protects personnel, and ensures market access in regulated regions | Impacto do ROI: Mitigates project risk from noncompliance penalties and simplifies insurance procurement.

Design modular montado em skid | Base Técnica: Preassembled structural steel skid with integrated walkways and maintenance platforms | Benefício Operacional: Significantly reduces civil works and onsite assembly time—plant can be operational within weeks of delivery | Impacto do ROI: Lowers total installed cost by up to 30% compared to traditional fieldbuilt foundations and structures.

Lubrificante Centralizado & Sistema Hidráulico | Base Técnica: Singlepoint greasing lines for key bearings and integrated hydraulic system for adjustment & compensação | Benefício Operacional: Simplifies routine maintenance schedules; enables quick setting adjustment and tramp iron release without downtime | Impacto do ROI: Reduces planned maintenance time by approximately 20%, aumentando as horas operacionais anuais disponíveis.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Typical NonCE Plant) | Nossa solução de planta de britagem de minério de ferro com marcação CE | Vantagem (% Melhoria) |
| : | : | : | : |
| Vida útil do forro (Minério Abrasivo)| ~450,000 MT throughput per set| ~600,000 MT throughput per set| +33% |
| Tempo médio entre falhas (MTBF)| ~800 horas| ~1.200 horas| +50% |
| Instalação & Tempo de comissionamento| 812 semanas| 35 semanas| ~60% mais rápido |
| Consumo de energia por tonelada| Linha de base (100%)| Aproximadamente 9295% da linha de base| 58% redução |
| Regulatory Market Access| Requires extensive retrofit & documentation| Full CE compliance from delivery| Eliminates retrofit cost & delay |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: 400 1,200 toneladas por hora (TPH), dependent on feed size distribution and ore characteristics.
Tipo de britador primário: Triturador de mandíbula de alternância única.
Abertura de alimentação: Up to 1,500mm x 1,200mm.
Tamanho máximo de alimentação: Up to 1,050mm edge length.
Faixa de configuração de descarga: 150 250mm CSS (Configuração lateral fechada).
Requisitos de energia: Potência total instalada aproximadamente 300 450 kW (crusher motor + motor alimentador + auxiliares).
Especificações de materiais: Crusher jaws in premiumgrade Manganese Steel (14%18%); classe de aço estrutural S355JR; wear plates on feed hopper.
Dimensões Físicas (Skid): Aprox.. Comprimento: 16m x Largura: 5m x Altura: 6eu (varia de acordo com o modelo).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; conexões do sistema de supressão de poeira padrão.

6. CENÁRIOS DE APLICAÇÃO

MidSized Magnetite Operation Expansion

Desafio: A Nordic mine needed to expand primary capacity but faced high local labor costs for extended onsite construction. Regulatory requirements mandated full CE compliance.
Solução: Installation of a preassembled skidmounted CE marked iron ore crushing plant with integrated dust suppression.
Resultados: The plant was commissioned in under four weeks postdelivery. It achieved permitted throughput immediately while reducing projected installation costs by approximately €150k.

Modernização da planta de processamento de hematita

Challenge An aging processing facility suffered from constant unplanned downtime in its primary section due to crusher failures and excessive liner wear on hard hematite ore.
Solution Replacement of the legacy primary setup with our heavyduty jaw crusher plant featuring centralized lube systems and reinforced liners.
Results Field data shows liner life improved from an average of ~380k tonnes to over 550k tonnes. Annual planned maintenance events were reduced from five to three directly increasing annual available operating time

Considerações Comerciais

Equipment Pricing Tiers are structured around throughput capacity core drive power
Nível I (900 TPH): Highcapacity configuration with premium components

Optional Features include advanced condition monitoring sensors onboard weighing systems automated grease systems specific wear package upgrades for highly abrasive ores

Service Packages range from basic commissioning support up through comprehensive multiyear scheduled maintenance plans including liner changeout services performed by factorytrained technicians

Financing Options are available including leasing structures that preserve capital expenditure lines or progressbased payment plans aligned with project milestones

Perguntas frequentes

Q Is this plant compatible with my existing secondary circuit conveyors
A Yes The discharge height conveyor interface points can be adapted during engineering Standard discharge heights are provided but modifications are possible prior to build

Q What is the expected impact on my overall plant availability
A Based on historical performance data this design improves primary section availability typically achieving >94 due primarily to increased component life reduced unscheduled stops

Q Does CE marking cover the entire electrical system
A Yes Full CE certification encompasses all mechanical electrical control aspects ensuring conformity with relevant EU directives essential for projects requiring European certification

Q Are wear parts readily available globally
A We maintain strategic parts inventories in key mining regions Lead times for critical wear parts like jaw liners average less than days supported by our global logistics network

Q What commercial terms are standard
A Standard terms involve progress payments against engineering milestones factory acceptance testing FAT shipment Final payment is due upon completion of successful site commissioning