1. ABERTURA ACIONADA POR PAINPOINT

Você está gerenciando uma operação comercial agregada onde é consistente, a produção de alto volume é crítica para a lucratividade? Your 250300 tph stone crushing plant faces significant operational pressures. Inconsistent feed material causes unexpected wear and crusher stalls, leading to costly, tempo de inatividade não planejado. Energy consumption per ton remains stubbornly high, erosão das margens. Meeting strict, dualgrade specifications for base and chip products often requires inefficient, multistage recrushing. Além disso, the total cost of ownership—from liner replacements to conveyor maintenance—accumulates faster than projected.

How do you increase plant availability beyond 92%? Can you reduce your cost per ton while maintaining precise product shaping? Is your current setup flexible enough to handle varying rock hardness without sacrificing throughput? The solution requires a system engineered not just for capacity, mas para previsível, efficient commercial production.

2. VISÃO GERAL DO PRODUTO

Esse 250300tph Turnkey Stone Crushing and Screening Plant is a stationary, hardrock processing solution designed for highvolume production of aggregates (05milímetros, 510milímetros, 1020milímetros, 2031.5milímetros) and other specification materials. Integra britagem primária, britagem secundária/terciária, triagem, and material handling into a coordinated system.

Fluxo de Trabalho Operacional:
1. Redução Primária: Alimentação de caminhões basculantes <750mm rock into a vibrating grizzly feeder which bypasses sub100mm fines and directs oversize to a robust primary jaw crusher.
2. Secundário & Britagem Terciária: Primary crushed material is conveyed to a cone crusher for intermediate reduction. A second cone crusher or impact crusher in closed circuit performs final shaping and size refinement.
3. Dimensionamento & Classificação: Material is routed to a multideck vibrating screen where it is precisely separated into finished product stockpiles.
4. Recirculação: Oversize from the screens is automatically returned via closedcircuit conveyors to the appropriate crusher for further processing.
5. Supressão de poeira: Sistemas de pulverização integrados nos pontos de transferência controlam as emissões de partículas.

Escopo de aplicação: Ideal para granito, basalto, river pebble, calcário, and other abrasive materials with compressive strength up to 350 MPa. Suitable for large quarry operations, apoio a grandes projetos de infraestrutura (rodovias, ferrovias), and dedicated commercial aggregate supply yards.

Limitações: Not designed for mobile or semimobile applications requiring frequent relocation. Site requires stable foundation preparation and adequate space for plant layout and stockpiling.

3. RECURSOS PRINCIPAIS

Sistema Inteligente de Controle de Alimentação | Base Técnica: Unidade de frequência variável (VFD) on feeder & level sensors | Benefício Operacional: Maintains optimal chokefeed condition for cone crushers automatically | Impacto do ROI: Aumenta o rendimento em 812% and reduces liner wear by up to 15%
Configuração do britador para serviço pesado | Base Técnica: Ajuste hidráulico & clearing on all crushers | Benefício Operacional: Enables rapid CSS changes for product sizing and safe clearing of tramp metal/stalling | Impacto do ROI: Reduces downtime for chamber clearing from hours to minutes
Controle Centralizado de Processos | Base Técnica: Automação baseada em PLC com IHM touchscreen | Benefício Operacional: Allows singleoperator monitoring of entire flow from a control room; logs production data | Impacto do ROI: Lowers labor costs and provides data for production optimization
Modular Electrical & Hydraulic Design | Base Técnica: Preassembled skids with quickdisconnect couplings | Benefício Operacional: Simplifica a instalação, comissionamento, and future maintenance access | Impacto do ROI: Reduces installation time by ~30% and lowers service costs
MultiStage Dust Suppression | Base Técnica: Pressurized spray nozzles at key transfer points with moisture sensors | Benefício Operacional: Effectively controls dust without overwetting material | Impacto do ROI: Ensures environmental compliance and protects downstream equipment

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (250300planta tph) | Esta solução de planta de 250.300 tph | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade de planta | 88 91% | 92 95%| +4% (Tempo de inatividade reduzido) |
| Consumo de energia (kWh/tonelada)| 1.8 2.2 kWh/t | 1.65 1.85 kWh/t| Até 12% (Energy Savings) |
| Vida útil do revestimento do britador (Rocha Abrasiva)| ~450 horas de operação| 520+ horário de funcionamento| +15% (Reduced Wear Cost) |
| Índice de formato do produto (Descamação)| >18% in chip products| <15% in chip products| Maior valor do produto |
| Tempo de reconfiguração (Mudança de CSS)| Ajuste manual de calço (~4 hrs)| Ajuste hidráulico (~30 min)| 87% (Flexibilidade Operacional) |

5.ESPECIFICAÇÕES TÉCNICAS

Capacidade de rendimento projetada: 250 300 toneladas métricas por hora (com base na densidade do material de ~1,6 t/m³)
Triturador Primário: Jaw Crusher Model JC1303 / Abertura de alimentação:1300x300mm / Tamanho máximo de alimentação: ≤750 mm
Trituradores Secundários/Terciários: Two units of Cone Crushers Model CC300 / Each with hydraulic adjustment & compensação
Unidade de triagem: Tripledeck Vibrating Screen Model VS2460 / Área da tela: ~14 sqm
Requisito de energia: Potência total instalada aproximadamente 650 kW; Mains connection recommended at400V/50Hz or480V/60Hz.
Principais especificações de materiais: Main frame construction Q345B steel; Conveyor belts EP630/4; Crusher liners Mn18Cr2 high manganese steel.
Dimensões Físicas (Aprox.): Overall layout length ~85m; width ~25m; max height ~12m.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; dust emission concentration at outlet ≤20mg/m³.

6\. CENÁRIOS DE APLICAÇÃO

Produção de Curso Base Rodoviário | Desafio:A national contractor required consistent,sustained production of Class A base course(031\.5milímetros)and chip sealing aggregates(510milímetros)from hard granite for a toll highway project.Plant stoppages directly threatened project timelines.| Solução:A turnkey250\300tph plant was installed featuring twostage cone crushing in closed circuit with precise screening.The automated control system allowed quick switching between product specifications.| Resultados:The plant achieved an average output of280tph over22months.Availability averaged94\.2%.The consistent cubical shape of the chip product reduced bitumen consumption by an estimated7%,noted by the paving contractor.

Commercial Quarry Expansion Challenge:A regional quarry operator needed to upgrade from150tph to meet new supply contracts but had limited space for expansion and needed to maintain production during phased commissioning.| Solução:The modular design of the250\300tph plant allowed it to be constructed parallel to the old line.Critical preassembled skids reduced onsite assembly time.The old line was decommissioned only after the new plant was fully operational.| Resultados:The expansion was completed with only48hours of total production stoppage.The new plant's energy efficiency reduced power costs by$0\.11per ton produced,increasing annual gross margin significantly.

Limestone Processing for Concrete Aggregates Challenge:A readymix concrete supplier's own aggregate plant struggled with excessive fines generation(<0\.075milímetros)and poor shape in the critical10\20mm fraction,increasing cement demand in their mixes.| Solução:The plant configuration prioritized lowwear,cubicalproduct crushing stages.An impact crusher was selected as the tertiary unit,and screen deck configurations were optimized to remove excess fines early.| Resultados:Fines generation was reduced by22%.The improved particle shape increased the workability of the concrete mix.Field data showed a potential3\5%reduction in cement usage while maintaining slump specifications.

CONSIDERAÇÕES COMERCIAIS

Pricing is structured around core configuration levels:

• Nível 1(Configuração básica):Inclui britador de mandíbula primário,britador de cone único,tela de três andares,transportadores básicos,and central control panel.Priced as acapital investmentfor standard materials like limestone.
• Nível 2(Configuração aprimorada):Adds secondary cone crusherfor full closedcircuit operation,intelligent VFD feed control,and enhanced dust suppression.Recommendedfor abrasive materials(granito,basalto).
• Nível 3(Configuração personalizada):Incorporates specific options such as washing systemsfor manufactured sand,finer screening decksfor specialized products,and extended weather protection enclosures.

Recursos opcionais incluem telemática de monitoramento remoto,mobile generator hookups,and automated lubrication systems.Service packages range from basic commissioningand operator trainingto comprehensive annual maintenance contracts with guaranteed parts availability.Financing options including equipment leasingand term loans are available through partnered financial institutions,making capital expenditure manageable against longterm supply contracts.

Perguntas frequentes

P:What if my feed material size or hardness varies frequently?
UM:The hydraulic adjustment on the crushers allows operators to change the Closed Side Setting(CSS)in minutes via the control panel.This adapts the crushing chamberto different conditions without stopping production,a key featureof this commercial stone crushing plantsolution.

Q.How many operators are requiredto run this plant?
A.The centralized PLC automationis designedfor singlestation control.One trained operatorin the control room can manage the entirecrushingandscreening process.Routine ground inspectionsare still recommended,but direct machinelevel operationis not required.

Q.Can this system integratewith our existing primary feedingor downstream equipment?
A.YES.The design includes standardized feedand discharge heights.Conveyor lengthsand transfer pointscan be modifiedduring engineering.We will review your site layoutto ensure compatibilitywith your current stockpile feedersor existing tertiary processing lines.

Q.What isthe typical installationand commissioning timeline?
A.For aprepared foundation site,the modular skidded components allow erectionin approximately8\10weeks.Commissioningand performance testingtypically takes an additional1\2weeks.This timeframe assumes all civil worksare complete prior todelivery.

P. As peças sobressalentes estão prontamente disponíveis,and what arethe lead times?
A.We maintaina strategic inventoryof highwear parts(placas de mandíbula,mantos,malhas de tela).For standard wear parts,the commitmentis shipmentwithin72hours.For major components,a stocklistwith guaranteed lead timesis providedwith themaintenance contract.

Q.What kindof trainingis providedfor our maintenance team?
A.Comprehensive trainingincludes both classroom instructionon system principlesand handson field training.It covers daily checks,troubleshooting usingthe HMI diagnostics,procedimentos de manutenção de rotina,and safe liner changeout protocols.Training documentationis supplied digitallyandin print