Import Crushing And Screening Equipment Manufacturers
1. ABERTURA ACIONADA POR PAINPOINT
Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo as margens do seu projeto? Na produção agregada, processamento mineral, e reciclagem, britagem e peneiramento ineficientes são o principal gargalo. Os desafios comuns incluem:
Tempo de inatividade excessivo para manutenção: Mudanças freqüentes de revestimento, falhas de rolamento, and conveyor issues halt your entire production line.
Gradação inconsistente do produto: Poor screening efficiency and improper crushing chamber dynamics lead to offspec material, causing product rejection and revenue loss.
Altos custos operacionais: Aumento do consumo de energia por tonelada, coupled with high wear part replacement frequency, directly impacts your bottom line.
Configuração de planta rígida: Os sistemas fixos não podem se adaptar às mudanças nos requisitos de matéria-prima ou do produto final, limitando a flexibilidade operacional.
O seu equipamento atual está resolvendo esses problemas, or is it the source of them? A estação de britagem primária certa não é apenas uma compra; it’s a strategic decision for longterm site profitability.
2. VISÃO GERAL DO PRODUTO: PRIMARY CRUSHING AND SCREENING STATION
This primary crushing and screening station is a fullyintegrated, trackmounted or modular system designed for the initial size reduction of runofmine ore, rocha de pedreira, or demolition concrete. Its workflow is engineered for continuous heavyduty operation:
1. Alimentar: Material is deposited via excavator or wheel loader into a robust vibrating grizzly feeder.
2. Pré-triagem & Esmagamento: The grizzly bypasses fines directly to a conveyor while oversize material is directed into the highcapacity jaw crusher.
3. Britagem Primária: The jaw crusher performs the first mechanical reduction using compressive force.
4. PostCrushing Screening: Crushed material is conveyed to an integrated screen for immediate separation into required product fractions.
5. Stockpiling or Secondary Conveyance: Sized fractions are stockpiled or conveyed to the next stage of processing.
Escopo de aplicação: Ideal para mineração de rocha dura, pedreiras agregadas, projetos de construção em grande escala, e C&D recycling operations requiring highvolume primary reduction.
Limitações: Não projetado para moldagem do produto final (tertiary crushing) or processing highly abrasive materials without specific liner configurations. Feed size must adhere to crusher opening specifications.
3. RECURSOS PRINCIPAIS
Direct Drive Jaw Crusher | Base Técnica: Eliminates Vbelts and associated components | Benefício Operacional: Reduces power transmission losses and removes routine belt tensioning/maintenance | Impacto do ROI: Os dados de campo aparecem até 10% menor consumo de combustível e 15% less scheduled maintenance time.
Independent PreScreen Module | Base Técnica: Twodeck vibrating grid mounted ahead of the crusher | Benefício Operacional: Removes fines and natural sand from the crusher feed, reducing chamber wear and increasing throughput of valuable midsize material | Impacto do ROI: Can extend manganese liner life by up to 30% and increase total station output.
Ajuste de configuração hidráulica (HSA) | Base Técnica: Wedgebased chamber adjustment via hydraulic cylinders | Benefício Operacional: Allows operators to change the crusher closedside setting (CSS) em baixo 2 minutes for precise product size control without stopping the plant | Impacto do ROI: Minimizes nonproductive time during product changeovers by over 90%.
HeavyDuty Feeder with Step Grizzly | Base Técnica: Reinforced feeder with stepped grizzly bars to prevent clogging | Benefício Operacional: Ensures consistent feed flow even with sticky or claybound materials, preventing bridging and feeder stall | Impacto do ROI: Maintains target throughput rates in challenging conditions, avoiding costly flow interruptions.
Integrated Plant Automation System (IPAS) | Base Técnica: PLCbased control with touchscreen interface monitoring all critical functions | Benefício Operacional: Fornece dados em tempo real sobre taxas de produção, consumo de energia, and operational status; enables singlepanel control for setup and troubleshooting | Impacto do ROI: Melhora a eficácia geral do equipamento (OEE) through better monitoring and reduces diagnostic time by an average of 50%.
Pontos de lubrificação centralizados | Base Técnica: Manifold system linking all major bearing points to a single station | Benefício Operacional: Permite segurança, rapid daily lubrication checks without requiring access around moving components | Impacto do ROI: Standardizes preventive maintenance routines, enhancing bearing life and reducing lubricationrelated failures.
4. VANTAGENS COMPETITIVAS
| Métrica de desempenho | Solução padrão da indústria | This Primary Crushing & Screening Station | Vantagem (% Melhoria) |
| : | : | : | : |
| Toneladas por hora (TPH) Eficiência| Reliant on optimal feed conditions only| Mantém >90% of rated TPH with variable/ sticky feed due to step grizzly design| +1520% sustained output |
| Custo da peça de desgaste por tonelada| Based on standard manganese composition| Utilizes sitespecific alloy analysis for jaw liners in highabrasion applications| Até 25% custo por tonelada triturada |
| Configurar / Configuration Time| Multiple machine positioning & cable connections required| Singlelift modules with prerigged electrical connections between units| 70% relocation time |
| Consumo de energia (kWh/tonelada)| Direct mechanical drive with fixed speed motors| Loadsensing hydraulics & direct electric crusher drive adjust power to demand| 8% uso médio de energia |
Based on comparative field trials in granite quarry applications.
5. ESPECIFICAÇÕES TÉCNICAS
Tipo de britador primário: Nordberg C106 Jaw Crusher
Abertura de alimentação: 1,060 milímetro x 700 milímetros (42” x 28”)
Tamanho máximo de alimentação: 600 milímetros (24”)
Configuração lateral fechada (CSS) Faixa: 70 200 milímetros
Faixa de capacidade: Até 500 MTPH (depende da densidade do material & CSS)
Unidade de energia: CAT C9 / C9.3 ACERT Tier 4 Motor diesel final
Potência Total Instalada: 224 kW
Feeder Type: Vibrating Grizzly Feeder VG43912V
Módulo de tela: Twodeck inclined screen TS303
Main Conveyor Width: 1,000 milímetros
Dimensões de Transporte (CxLxA): ~19m x ~3m x ~4m
Peso Operacional: ~45 toneladas
Faixa de temperatura operacional: 25°C a +40°C
6. CENÁRIOS DE APLICAÇÃO
Expansão da Pedreira de Agregados de Granito | Desafio: Existing fixed primary plant could not service new pit face location without major infrastructure cost; mobile solutions lacked necessary throughput and prescreening. Solução: Deployment of a trackmounted primary crushing and screening station fed directly by excavator at the new face. Resultados: Eliminated need for costly ramp construction and dump truck haulage to old plant. Obteve um rendimento consistente de 380 Mtph of minus200mm base material with improved yield of valuable railway ballast fraction due to integrated screening.
Projeto de infraestrutura em larga escala (Dam Construction) | Desafio: Processing riverrun gravel with high sand content led to rapid crusher wear choke points in traditional setups. Solution Implementation of a modular primary station featuring an independent prescreen module ahead of the jaw crusher Results Prescreen removed over 25% of sand/fines prior to crushing reducing abrasive wear Throughput increased by18% as crusher processed only oversize Wear part replacement intervals extended by approximately40%
7 CONSIDERAÇÕES COMERCIAIS
Pricing for a primary crushing station varies significantly based on configuration:
- Base Configuration Includes core jaw crusher basic feeder engine chassis essential conveyors PLC start/stop controls Tier pricing typically begins in range appropriate for this capital equipment class
- Dust suppression system package including water tank spray bars
- Magnet installation over discharge conveyor ferrous metal removal
- Radio remote control unit for independent feeder/crusher operation from ground level
- Extended wear part kits stock
- Comprehensive Extended Warranty covering major components years unlimited hours
- Scheduled Maintenance Plan providing fixed cost annual inspections parts labor
- On Site Operator Training Program days hands instruction
Optional Features That Add Value:
Pacotes de serviços disponíveis:
Financing Options Flexible capital solutions include equipment leasing long term rental purchase leaseback structures tailored support cash flow management project timelines
8 Perguntas frequentes
What type/size of excavator is recommended as a feeder?
A minimum operating weight class excavator equipped with suitable bucket capacity ensure consistent choke feeding maximize crusher efficiency productivity
How does this system handle reinforcing bar rebar in concrete demolition waste?
While jaw can process reinforced concrete integrated overband magnet discharge conveyor effectively removes liberated ferrous metals protecting downstream conveyors secondary crushers
What are typical delivery lead times after order confirmation?
Standard configurations have confirmed lead time weeks subject build slot availability engineering review Custom modular designs may require additional weeks detailed engineering fabrication
Is operator training provided with purchase?
Yes comprehensive onsite training program conducted commissioning covers daily operation routine maintenance safety procedures troubleshooting using actual plant systems
Can this station be integrated into existing fixed plant circuit as temporary primary unit?
Yes stations are designed standalone mobility can be positioned feed directly into existing secondary tertiary circuits via discharge conveyor ideal use during planned upgrades maintenance existing primary crushers