1. ABERTURA ACIONADA POR PAINPOINT

Você está gerenciando uma operação de produção agregada de médio a grande porte e enfrentando gargalos persistentes que prejudicam a lucratividade?? Para gerentes de fábrica e empreiteiros de engenharia, uma planta de britagem de pedra de 250.300 tph é um ativo crítico, ainda assim, desafios operacionais comuns impactam diretamente seus resultados financeiros. Considere estes problemas frequentes:
Taxa de transferência inconsistente & Tempo de inatividade: Unplanned stoppages due to feeder blockages, crusher overloads, or conveyor misalignment can cost thousands per hour in lost production and idle labor.
Alta operacional & Custos de manutenção: Substituição frequente de peças de desgaste, alto consumo de energia por tonelada produzida, and the need for specialized maintenance crews steadily increase your cost per aggregate ton.
Formato ruim do produto & Controle de gradação: Inconsistent output leads to excess fines or outofspec material, reducing the market value of your end product and causing rejections.
Rigid Plant Layout & Limites de escalabilidade: Fixed designs struggle to adapt to changing feed material hardness or required product mixes, forcing costly retrofits or operating below optimal capacity.

How do you achieve stable, highyield production while controlling costs and ensuring final product quality? The solution lies in a robustly engineered 250300tph stationary crushing plant designed for predictable performance.

2. VISÃO GERAL DO PRODUTO

This solution is a complete stationary stone crushing and screening plant engineered for a nominal output of 250 para 300 toneladas métricas por hora (tph) de agregado acabado. It is designed as a primarytotertiary processing system for mediumhard to hard stones like granite, basalto, e calcário.

Fluxo de Trabalho Operacional:
1. Britagem Primária: Material de alimentação grande (≤750 mm) is reduced by a heavyduty jaw crusher or gyratory crusher.
2. Secundário & Britagem Terciária: The primary crushed material is further processed by cone crushers for size reduction and improved particle shape.
3. Triagem & Classificação: Vibrating screens separate material into precise size fractions, routing oversize back to crushers and directing onspec product to final stockpiles.

Escopo de aplicação: Ideal para grandes operações em pedreiras, major infrastructure project support (rodovias, ferrovias), and commercial aggregate supply yards requiring highvolume, saída consistente.

Principais limitações: Feed material hardness must be within specified limits (por exemplo, até 300 Resistência à compressão MPa). Plant requires stable foundation preparation and gridbased power connection. Not designed for mobile or frequent relocation.

3. RECURSOS PRINCIPAIS

Sistema Inteligente de Controle de Alimentação | Base Técnica: Unidade de frequência variável (VFD) on primary feeder with level sensors | Benefício Operacional: Prevents crusher cavity overload and minimizes bridging, ensuring smooth material flow | Impacto do ROI: Reduz o tempo de inatividade não planejado em até 15% and improves crusher liner life

Laminated Crushing Chamber Design | Base Técnica: Multilayer crushing cavity geometry in cone crushers | Benefício Operacional: Produces superior particle shape with lower flakiness index and controlled fines generation | Impacto do ROI: Increases premium product yield by 812%, enhancing sales revenue

Lubrificação Centralizada & Sistema Hidráulico | Base Técnica: Singlepoint lubrication stations with automated timers and pressure monitoring | Benefício Operacional: Ensures critical bearing points are serviced consistently, reducing failure risk | Impacto do ROI: Lowers bearingrelated breakdowns by an estimated 25% and extends service intervals

HighStrength Modular Conveyor Framework | Base Técnica: CADoptimized truss design using hightensile steel | Benefício Operacional: Provides exceptional stability under load, reducing vibration and misalignment issues | Impacto do ROI: Decreases conveyor maintenance time by approximately 20% over the plant lifecycle

PLCBased Automated Process Logic | Base Técnica: Controlador lógico programável com interface homem-máquina (IHM) for sequence control and interlocking | Benefício Operacional: Allows singleoperator oversight of startup/shutdown sequences and provides fault diagnostics | Impacto do ROI: Optimizes power use during operation cycles and reduces labor requirements for plant control

HeavyDuty Vibrating Screen with QuickChange Decks | Base Técnica: Rubber shear mounts and sidetensioned screen media attachment system | Benefício Operacional: Provides efficient sizing with reduced noise/vibration transmission; enables faster screen cloth replacement | Impacto do ROI: Cuts screen maintenance downtime by up to 40% por evento de mudança

Sistema integrado de supressão de poeira | Base Técnica: Nozzle arrays at transfer points connected to a highpressure pump system | Benefício Operacional: Effectively controls airborne particulate at primary dust generation sources | Impacto do ROI: Garante a conformidade com as regulamentações ambientais, avoiding potential fines and improving site working conditions

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (250300planta tph) | This 250300tph Stone Crushing Plant Solution | Vantagem (% melhoria) |
|||||
| Eficácia geral do equipamento (OEE) | ~76% | Target ≥84% | +10.5% |
| Consumo de energia (kWh/tonelada processada) | Varia muito; baseline = X | Optimized system design reduces baseline |7% para 12% |
| Vida útil da peça de desgaste do britador (Forros de manganês)| Based on abrasive feed | Improved chamber design & seleção de liga |15% Custo por tonelada |
| Tempo médio entre falhas (MTBF) Key Conveyors ~1,200 hours ~1,650 hours +37.5% |
| Índice de formato do produto (Flakiness) Tipicamente >20% Mantém <15% 25% Improvement in Cubicity |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade nominal: 250 – 300 tph (varies based on feed material hardness & required product gradation).
Opções do britador primário: Maldito Mandíbula (PE900×1200) ou triturador giratório; Feed Opening up to 750mm.
Trituradores Secundários/Terciários: Multicylinder Hydraulic Cone Crushers.
Equipamento de triagem: Tripledeck heavyduty circular motion vibrating screens; Total screening area ≥20m².
Potência Total Instalada: Aproximadamente 550 – 650 kW (depende da configuração).
Principais especificações de materiais: Primary frame construction Q345B steel; Highwear components use Mn18Cr2 or equivalent alloys; Conveyor belts rated for minimum PIW 800.
Pegada geral da planta (CxL): Approximately 85m x 65m (dependente do layout). Height restrictions apply (~25m max).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; Dust emission control achieves ≤20mg/m³ at key points.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Challenge A quarry needed to increase production from 200tph to a consistent 280tph of road base and concrete aggregates but had limited space for plant expansion.
Solution Implementation of a compact vertical layout using this configured plant with multicylinder cone crushers for secondary/tertiary stages.
Results Achieved steadystate output of 290tph within the existing footprint. Product cubicity met the highest local specification standards.

LargeScale Highway Construction Support

Challenge A contractor required an onsite crushing setup capable of processing blasted limestone at high volume while maintaining strict gradation bands for multiple subbase layers.
Solution Deployment of this complete stationary crushing plant including advanced screening modules with precise deck configurations.
Results The plant supplied over 1.2 million tons of spec material across three years with less than five percent deviation from required gradation curves.

7. CONSIDERAÇÕES COMERCIAIS

Our solutions are offered in tiered configurations:
Camada de configuração padrão: Inclui módulos de britagem de núcleo,screening units,and basic PLC control.Priced as a turnkey package.
Nível de alta eficiência: Adds intelligent feed systems,crusher automation settings,and premium wear materials.Initial investment yields lower longterm operating costs.
Custom Engineering Tier: For nonstandard applications requiring specific layouts or special material handling components.Priced upon project engineering review.

Optional features include advanced dust collection baghouses,tiremounted mobile primary units for flexible feeding,and remote monitoring telematics packages.Service agreements range from basic scheduled maintenance plans to comprehensive annual partsandlabor coverage.Financing options including equipment leasing are available through our partners.

8. Perguntas frequentes

What are the primary power requirements?
A stable threephase industrial power supply is required.Total connected load typically ranges from550to650kW.Detailed electrical schematics are providedfor grid connection planning.

Can this plant process river gravel or very abrasive materials?
While designedfor hard rock,the wear package can be specifiedwith enhanced alloysfor highly abrasive feeds.Consult our engineering teamfor specificmaterial test analysisand configuration recommendations.

What is the typical installationand commissioning timeline?
From foundation handoverto full production,the process typically requires8to12weeks.This includes mechanical erection,conexão elétrica,system calibration,and operator training conductedby our engineers.

Do you provide spare parts support globally?
We maintaina centralized spare parts depotand workwith regional logistics partners.We guarantee availabilityof critical wear partsand offera guaranteed48hour dispatchfor stocked items under service agreements.

How does thisplant handle variationsin feed sizeor hardness?
The PLCcontrolled system allows adjustmentsof crusher settings(via the HMI)and feeder rates.The hydraulic adjustmenton cone crushers enables quickcompensationfor changesin material characteristicsto maintainoutput quality