1. ABERTURA ACIONADA POR PAINPOINT

Gerenciar uma pedreira ou planta de processamento de calcário apresenta desafios distintos que impactam diretamente seus resultados financeiros. When it comes to primary size reduction, inefficient or unreliable equipment can create cascading operational failures. Você está experimentando:
Tempo de inatividade excessivo para manutenção? Mudanças freqüentes de revestimento, unexpected breakdowns, and lengthy service intervals on your primary crusher halt the entire upstream flow, custando milhares por hora em perda de produção.
Unpredictable Product Sizing? Inconsistent output from the primary stage forces secondary and tertiary crushers to work harder, increases recirculating load, and jeopardizes final product specifications critical for your customers.
Altos custos operacionais devido à abrasão? The silica content in limestone is notoriously abrasive. Premature wear on crusher components leads to skyrocketing spare parts inventories and labor costs for replacement.
Consumo ineficiente de energia? An illsuited or outdated primary crushing solution can draw excessive power without delivering proportional throughput, tornando a energia um dos seus maiores custos incontroláveis.
Bottlenecks in Feed Handling? Inability to process large, irregular quarryrun rock efficiently creates pileup at the primary station, limiting loader efficiency and overall site throughput.

Selecting the correct primary crushing solution is not just an equipment purchase; it is a strategic decision for longterm site profitability.

2. VISÃO GERAL DO PRODUTO

O [Nome da sua empresa] Triturador de mandíbula primário para serviço pesado is engineered as the first critical stage in fixed or semimobile limestone processing plants. It is designed to accept large feed material (quarryrun rock) directly from the mine face and perform reliable, highvolume reduction to a manageable size for downstream conveying and secondary crushing.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Quarryrun limestone (até o tamanho de feed especificado) is dumped via haul truck or loader into the crusher’s vibrating grizzly feeder (VGF VGF), which removes fines and directs oversize material into the crushing chamber.
2. Esmagamento por compressão: Um robusto, oscillating manganese steel jaw plate exerts immense compressive force against a fixed jaw plate, fracturing the limestone along its natural cleavage planes.
3. Ajuste de configuração de descarga: O material triturado sai através de uma abertura ajustável na parte inferior da câmara (a configuração fechada), determinar o tamanho máximo do produto. Hydraulic adjustment systems allow for quick changes without downtime.
4. Transporte de Produto: The sized discharge is transported via belt conveyor to the next stage in your processing circuit.

Escopo de aplicação & Limitações:
Escopo: Ideal for hightonnage quarry primary crushing of blasted limestone with compressive strengths up to 350 MPa. Suitable for both stationary plants and trackmounted mobile applications.
Limitações: Not designed for highly abrasive materials with extreme silica content without specific liner configurations. Requires prepared feed; tramp metal or uncrushable objects can cause damage without proper protection systems.

3. RECURSOS PRINCIPAIS

Câmara de britagem profunda & Cinemática Otimizada | Base Técnica: Increased feed opening volume and aggressive elliptical stroke motion | Benefício Operacional: Enables higher capacity per cycle and promotes a strong "rockonrock" crushing action for better particle shape | Impacto do ROI: Higher throughput per operating hour reduces costperton metrics.

Estrutura de aço fabricada para serviços pesados | Base Técnica: Stressrelieved weldments and reinforced ribbing | Benefício Operacional: Provides longterm structural integrity under constant highload cycling, minimizando a fadiga da estrutura e problemas de alinhamento | Impacto do ROI: Extends crusher service life beyond decades, protegendo o investimento de capital.

Ajuste de alternância hidráulica & Sistema de compensação | Base Técnica: Replaces traditional mechanical toggle plates with a dualacting hydraulic cylinder system | Benefício Operacional: Permite que os operadores ajustem o CSS com segurança em minutos e eliminem bloqueios sem intervenção manual | Impacto do ROI: Reduz o tempo de inatividade improdutivo em até 80% during routine adjustments and clearing events.

Extinguido & Tempered Manganese Steel Jaw Dies | Base Técnica: Alloy composition and heat treatment process creating a workhardening surface | Benefício Operacional: Jaw plates develop a hard, wearresistant layer during operation that extends service life in abrasive limestone applications | Impacto do ROI: Lowers costperton for wear parts by increasing liner lifecycles between changes.

Base de motor integrada & Proteção de transmissão por correia | Base Técnica: Unified baseplate design with full perimeter guarding | Benefício Operacional: Simplifica o alinhamento da instalação, reduz a pegada, and ensures maximum operator safety around drive components | Impacto do ROI: Cuts installation time/costs by up to 30% e mitiga o risco de paradas relacionadas à segurança.

Sistema de lubrificação automatizado centralizado | Base Técnica: Programmable lubrication unit with distribution blocks to all key bearings | Benefício Operacional: Delivers precise grease volumes at set intervals without manual intervention, ensuring optimal bearing health | Impacto do ROI: Prevents catastrophic bearing failure—the leading cause of major crusher repair—directly reducing maintenance costs.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Média) | Nossa solução primária de britador de mandíbula | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade / Tempo de atividade | 8590% (paradas planejadas/não planejadas) |> 94% disponibilidade documentada| +510% horas mais produtivas |
| Vida útil do revestimento (Calcário Abrasivo) ~2530k MTON| ~40k MTON before replacement required| +33% vida útil mais longa |
| Consumo de Energia por Tonelada Moída| Linha de base kWh/tonelada| Até 15% lower kWh/tonne measured in field trials| 15% operational energy cost |
| Tempo de ajuste CSS (Mecânico versus. Hidráulico)| 46 horas com trabalho manual|< 30 minutos através do sistema hidráulico| 90% adjustment downtime |
| Tramp Iron Protection Reaction Time| Shear pin/breakable toggle requires inspection & substituição| Automatic hydraulic release & reset in < 60 segundos| Nearzero damage from uncrushables |

5. ESPECIFICAÇÕES TÉCNICAS

Designação do modelo: HDJ1250
Abertura de alimentação: 1250mm x 950 mm (49" x 37")
Tamanho máximo de alimentação: 800milímetros (31") caroço
Configuração lateral fechada (CSS) Faixa: 150mm 250 mm (6" 10")
Faixa de capacidade (@ dado CSS): 450 750 MTPH
Requisitos de energia da unidade: 200 kW (250 HP), motor elétrico
Peso total (Triturador apenas): ~62.000kg (136,700 libras)
Construção de moldura: Hightensile steel plate (>350 Rendimento em MPa), aliviado do estresse.
Haste & Rolamentos: Eixo principal em liga de aço forjado; rolamentos autocompensadores de rolos superdimensionados.
Faixa de temperatura operacional: 20°C a +45°C (4°F a +113°F)
Observação: As especificações variam de acordo com o modelo; consult engineering datasheets for exact figures.

6. CENÁRIOS DE APLICAÇÃO

Expansão de pedreira agregada em grande escala

Desafio: A major aggregate producer needed to increase plant throughput by 40% but was constrained by an aging primary crusher causing weekly unplanned downtime.
Solução: Installation of two HDJ1250 Primary Jaw Crushers in parallel configuration as the new plant cornerstone.
Resultados: Atingiu um rendimento sustentado de >1,400 MTPH of minus10” material. A disponibilidade da planta aumentou de ~82% para mais 95%, meeting expansion targets within one fiscal year.

Processamento de matérias-primas de fábrica de cimento

Desafio: A cement plant’s existing primary crusher struggled with highsilica limestone blend, causing severe jaw plate wear every six weeks and unpredictable maintenance costs.
Solução: Replacement with our HDJseries crusher equipped with XtraTough manganese jaws and automated greasing.
Resultados:Liner life extended to an average of nine weeks—a >50% improvement—stabilizing maintenance schedules and reducing annual wear parts expenditure by an estimated $85,000 USD.

Contratação de britagem portátil

Desafio:A contracting company required a highly mobile yet rugged primary unit capable of quick setup on multiple shortduration limestone quarry projects across varying rock hardness.
Solução:A trackmounted version of our heavyduty jaw crusher featuring onboard power/hydraulics.
Resultados:The unit achieved full operational status within one hour of arrival on site at multiple locations.Consistent product gradation improved client satisfaction,and fuel efficiency data showed a12% reduction comparedto previous equipment over identical projects

7.CONSIDERAÇÕES COMERCIAIS

Níveis de preços:
• Base Configuration(HDJ1250):Inclui triturador de núcleo,acionamentos de motor,Protetores de correia em V,and basic tooling.Positioned as acapital investmentfor new plant buildsor direct replacements .
• Premium Package(HDJ1250P):Adds integrated automatic greasing system ,hydraulic adjustment/clearing ,andwear monitoring sensors .Recommendedfor operations prioritizingmaximized uptimeand predictive maintenance .
• Portfolio Solution(HDJTracked):Complete trackmounted chassiswith onboard gensetand feeder .Pricedas aturnkey mobileprimary station .

Recursos opcionais& Atualizações:
• Dust Suppression Kit(highpressure spray bars)
• Rock Breaker Boom& Hammer mounting provisions
• Advanced Condition Monitoring(remote vibration/temperature telemetry)
• Special Alloy Linersfor extreme abrasion applications

Pacotes de serviços:
• Platinum Support Plan:Cobre inspeções programadas ,preferential parts dispatch ,and annual health checkswith guaranteed response times .
• Wear Parts Agreement:Predictablecostperton contractfor all manganese wear components ,including inventory management .
Opções de financiamento:
Flexible commercial terms are available including capital lease ,arrendamento operacional ,and projectbased financing structures typically ranging from36to72months .Our financial partners can structure solutions basedon cash flow preservation objectives .

8.Perguntas frequentes

P:What if my current secondary crushers aren't sizedto handlethe increased outputfromyourprimary jaw?
UM：Our application engineering team conducts full circuit analysis.We can specify amodel that optimizes total system flow rather than creatinga bottleneck.Downstream compatibilityis afundamental partof our proposal process .

P：How doesthe automated greasing systemhandle differentoperating temperatureswhich affect grease viscosity?
UM：The systemis equippedwith viscosity compensationand heatersfor coldclimate operations.Field data shows consistent lubricant deliveryacross the specifiedoperating rangeensuring bearing protection .

P：Are there financing optionsavailablethat alignwithmysite's seasonal cash flow?
UM：Yes.We offer structured payment plansincluding seasonal deferralswhich are commonin aggregate production.Customized termscan be developedbasedon yourprojected production cycles .

P：Whatisthe typical lead timefrom orderto commissioningfor astationary plant installation?
UM：For standard modelslead timesare currently16–20weeks.Comprehensive foundation drawingsand installation manualsare providedwellin advanceof shipmentto facilitate site preparation .

P：Can thiscrusherbe integratedinto myexisting PLC/plant automation system?
UM：Yes.The unitcomes standardwith hardwired start/stopandsignal interfacesfor leveljamsand temperature.Optionalsensor packagesprovide analogoutputs(e.g.,CSS positionliner wear)for fullSCADA integration .

P：Whatisthe expected noise levelduring operationand arethere mitigation options?
UM：Noise emissionsat7metersare typically<85dBA.Sounddampening enclosuresanda lownoise Vbelt drive systemare availableas optionsto meet strict site regulations .

P：How doesyourcompany supportpartslognosticsin remote locations?
UM：We maintainstrategic regionalparts warehouseswith critical inventory.For registered support plan customerswe guarantee shipmentof critical breakdown partswithin24hoursfrom orderconfirmationto major logistics hubs