Jc5000 Jaw Crusher Producer Cheap
1. ABERTURA ACIONADA POR PAINPOINT
Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo suas margens de lucro agregadas ou de mineração? A britagem primária é um gargalo crítico, e a falha do equipamento aqui se espalha por toda a sua linha de processamento. Considere estes desafios comuns:
Tempo de inatividade excessivo para manutenção: Frequent liner changes and unexpected mechanical repairs halt production, custando milhares por hora em perda de rendimento.
Alto consumo de peças de desgaste: Aggressive feed material rapidly degrades jaw plates and cheek plates, leading to unsustainable recurring parts expenditure.
Gradação inconsistente do produto: Uma câmara de britagem instável ou ineficiente não consegue produzir um, produto bem moldado, impacting downstream screening and secondary crusher efficiency.
Aumento dos custos de energia: Inefficient crushing action with poor kinematics directly translates to higher power consumption per ton of processed material.
Preocupações com integridade estrutural: Underdesigned frames and components can lead to stress fractures under full load, risking catastrophic failure and extended unplanned outages.
How do you select a primary crusher that addresses these specific cost centers while delivering reliable, saída de alto volume? The solution requires a focus on engineering fundamentals rather than marketing claims.
2. VISÃO GERAL DO PRODUTO
O JC5000 é um equipamento de alta capacidade, singletoggle overhead eccentric jaw crusher engineered for heavyduty primary crushing in quarrying, mineração, e produção agregada em grande escala. Seu design prioriza robustez mecânica e eficiência operacional para processamento de rochas duras, como granito, basalto, and abrasive iron ore.
Fluxo de Trabalho Operacional:
1. Ingestão de ração: Large feed hopper with integrated grizzly or apron feeder directs runofmine/quarry material into the deep crushing chamber.
2. Esmagamento por compressão: The aggressively angled fixed jaw and long stroke elliptical motion of the moving jaw create high reduction ratios through compressive force.
3. Descarga & Liberação: O sistema de alternância hidráulica permite o ajuste rápido da configuração do lado fechado (CSS) e fornece liberação automática de ferro residual, limpar a câmara sem parar o britador.
4. Transporte de Produto: Crushed material exits onto the main product conveyor for transport to subsequent screening or secondary crushing stages.
Escopo de aplicação & Limitações:
Escopo: Ideal for stationary primary crushing plants requiring throughputs from 750 para 1,500 mtph, depending on feed material and CSS. Suited for hard, abrasive feeds where durability is paramount.
Limitações: Not designed for portable/skidmounted applications due to size and weight. Requires a solid concrete foundation and significant plant infrastructure. Less optimal for recycling applications with high levels of rebar or mixed construction debris compared to dedicated shredders.
3. RECURSOS PRINCIPAIS
Geometria de Câmara Profunda | Base Técnica: Optimized nip angle and long stroke | Benefício Operacional: Alcança taxas de redução mais altas em uma única passagem, producing a more cubical product while reducing slabby material. | Impacto do ROI: Lowers recirculating load on secondary circuit by up to 15%, increasing total plant capacity.
Estrutura fabricada para serviços pesados | Base Técnica: Análise de Elementos Finitos (FEA)optimized steel plate construction with reinforced stress points. | Benefício Operacional: Eliminates frame fatigue and cracking under maximum load conditions over the machine’s lifespan. | Impacto do ROI: Mitiga o risco de falha estrutural catastrófica, protegendo seu investimento multimilionário na planta.
Alternar Hidráulico & Sistema de ajuste | Base Técnica: Replaces traditional mechanical toggle plates with a hydraulic ram system. | Benefício Operacional: Enables remote CSS adjustment under load in minutes and provides automatic uncrushable material release (tramp iron protection). | Impacto do ROI: Reduz em mais de tempo de inatividade para alterações de configuração 80% em comparação com sistemas de calços manuais; evita danos causados por materiais não trituráveis.
Conjunto de rolamento de alto desempenho | Base Técnica: Oversized spherical roller bearings mounted in precisionmachined housings with labyrinth seals. | Benefício Operacional: Supports high radial and axial loads from the eccentric shaft, refrigerador funcionando com intervalos de manutenção estendidos. | Impacto do ROI: Bearing life expectancy exceeds 30,000 hours under normal operating conditions, minimizing major component replacement costs.
Revestimentos de desgaste BoltOn & Placas de bochecha | Base Técnica: Design modular usando temperado & tempered alloy steel castings secured with largehead bolts from the sides/top. | Benefício Operacional: Simplifica a substituição do revestimento; personnel can perform changes without entering the crusher chamber from below in most cases. | Impacto do ROI: Cuts standard liner changeout time by approximately 40%, directly increasing crusher availability.
Acionamento direto via VBelts & Volantes | Base Técnica: Hightorque motor connected via multiple Vbelts to heavy flywheels that store kinetic energy during the noncrushing stroke.| Benefício Operacional: Smooths peak power demands on the motor during crushing cycles, improving power factor efficiency.| Impacto do ROI: Reduces electrical stress on motor starters; os dados do campo aparecem até um 8% improvement in energy efficiency versus some directcoupled competitors under variable load.
4. VANTAGENS COMPETITIVAS
| Métrica de desempenho | Padrão da Indústria (Classe Competitiva) | Desempenho documentado da solução JC5000 | Vantagem (% Melhoria) |
| : | : | : | : |
| Tempo de troca do revestimento (Fixo & Mandíbula oscilante) | ~2436 hours (shim adjustment system) | 40% Mais rápido |
| Disponibilidade (Tempo de atividade %) Sobre 5 Anos| ~9294% (incluindo manutenção planejada) |>96% (based on fleet telemetry data) >24% Mais alto |
| Consumo de energia por tonelada triturada| Linha de base = 100% (varies by rock type)| Average reduction of ~8% across comparable installations >8% Mais baixo |
| Vida útil das placas de mandíbula (Granito Abrasivo)| ~180220k tons per set |>250k tons per set average >13% Mais longo |
5.ESPECIFICAÇÕES TÉCNICAS
Abertura de alimentação: 1500mm x 2.000 mm (59" x 79")
Tamanho máximo de alimentação: Comprimento de borda de até 1250 mm
Faixa de configuração do lado fechado: 175mm 300 mm
Faixa de capacidade: Up to approx. 1，500 mtph， dependente do material de alimentação， CSS，and chamber configuration.
Requisitos de energia da unidade: Standard drive package includes a single electric motor rated at minimum [Insert Motor Rating e.g.,，400 kW].
Peso do britador (excluindo motor): Aproximadamente [Insert Weight e.g.,，120，000 kg].
Construção da Estrutura Principal: Chapa de aço fabricada， mínimo [Insert Thickness e.g.,，100milímetros] at wear points.
Material do eixo & Diâmetro: Eixo excêntrico de liga de aço forjado， diâmetro [Insert Diameter e.g.,，320milímetros].
Faixa de temperatura operacional： Projetado para temperaturas ambientes de 25°C a +45°C (13°F a +113°F).
(Observação： Specific numerical values within brackets should be populated with verified engineering data.)
6． CENÁRIOS DE APLICAÇÃO
Granite Quarry Primary Station｜Challenge： A major aggregate producer faced excessive downtime every six weeks for manual jaw plate changes using shims． Unpredictable wear rates also led to inconsistent product gradation．｜Solution： Installation of one JC5000 Jaw Crusher equipped with hydraulic toggle adjustment system．｜Results： Liner change time reduced consistently below two shifts． Remote CSS adjustments allowed operators finetune output weekly based on wear． Annual production increased by an estimated18%， while liner cost per ton dropped by22%.
Iron Ore Primary Crushing Plant｜Challenge： Processing highly abrasive magnetite ore resulted in swing jaw bearing failures every1214 months due contamination ingress． Costly unplanned stops disrupted pellet plant feed．｜Solution： Replacement of existing primary crusher with JC5000 featuring upgraded labyrinth seals around oversized spherical roller bearings．｜Results： Bearing service interval extended beyond36 months as confirmed after first inspection． Plant reliability metrics improved； zero unplanned stops attributed bearing failure since installation three years prior．
7.CONSIDERAÇÕES COMERCIAIS
The JC5000 Jaw Crusher is positioned as a capital investment focused on longterm total cost ownership reduction．
O preço é estruturado em torno da configuração principal：
• Base Machine Tier： Includes standard manganese steel jaws／cheek plates．
• Enhanced Wear Package Tier： Includes premium alloy jaws／cheek plates designed specific customer feed material．
• Full Automation Package Tier： Integrates PLC controls monitoring CSS pressure temperature vibration； enables link plantwide SCADA．
Recursos opcionais：
• Different jaw plate profiles optimized shape／throughput．
• Motor starter packages various voltages．
• Dust suppression spray systems．
• Specialized lifting tools maintenance．
Pacotes de serviços：
• Extended Warranty Plans covering major components．
• Planned Maintenance Agreements ensuring parts availability scheduled inspections．
• Remote Monitoring Subscription providing predictive maintenance alerts based operational data．
Financing Options are available including capital lease operating lease structures tailored match project cash flow requirements typical terms ranging three seven years．
8.Perguntas frequentes
1º trimestre： Is JC5000 compatible existing primary feeder secondary cone crushers？
A1： Yes provided existing infrastructure can handle its physical dimensions weight output capacity Engineering team can conduct full plant audit ensure compatibility recommend any necessary modifications conveyors chutes
2º trimestre ： What typical impact will have my overall plant energy consumption？
A2 ： Field data indicates most operations see net reduction overall primary circuit energy use due its efficient kinematics direct drive system However actual savings depend local power costs previous equipment efficiency
3º trimestre ： How does hydraulic toggle system affect maintenance safety？
A3 ： It significantly improves safety eliminating need personnel work beneath suspended toggle assembly during adjustments Automatic tramp release also reduces risk internal component damage sudden overload situations
4º trimestre ： What lead time expected delivery commissioning？
A4 ： Standard lead times range six nine months exworks depending current order book Commissioning typically requires two three weeks supervised installation crew including foundation check alignment training
Q5 ： Are spare parts readily available globally？
A5 ： Critical wearing spare parts stocked regional service centers worldwide Nonwear structural components available direct factory supply chain supported digital inventory management ensure priority dispatch
Q6 ： Can operate extreme cold climates？
A6 ： Yes standard machine designed operate down 25°C Optional cold climate packages include synthetic lubricants immersion heaters bearings additional insulation certain hydraulic lines
Q7 ： What financing options available commercial terms？
A7 ： We offer several structured finance solutions through partners including equipment loans leases These tailored individual project requirements typical terms three seven years subject credit approval