1. ABERTURA ACIONADA POR PAINPOINT

Are your iron ore processing margins being eroded by persistent, tempo de inatividade não planejado? Commercial operators and plant managers face significant financial pressure from equipment that cannot withstand the abrasive reality of highvolume iron ore. Os desafios comuns incluem:
Desgaste Excessivo & Falha de componente: Standard crushing chambers and liners degrade rapidly under continuous Taconite or Hematite load, leading to frequent shutdowns for maintenance and high parts replacement costs.
Taxa de transferência inconsistente & Gradação do produto: Fluctuations in feed size or hardness result in poor control over final product sizing, causing bottlenecks in downstream grinding circuits and reducing pellet or sinter plant efficiency.
Alto Consumo de Energia por Tonelada: Older or improperly configured crushing stages consume disproportionate power, directly impacting operational expenditure and carbon footprint.
Configuração de planta rígida: Fixed crushing circuits struggle to adapt to varying ore body characteristics or market demands for different product specifications, limitando a flexibilidade operacional.

Is your primary crushing station a source of cost or a driver of profit? The solution lies in precision engineering applied directly to the unique demands of iron ore.

2. VISÃO GERAL DO PRODUTO

This content details a fully customizable, heavyduty stationary crushing plant solution engineered explicitly for hightonnage iron ore processing. The system is designed as a primary or primary/secondary stage unit, built around a core gyratory or jaw crusher configured for maximum abrasion resistance and volumetric throughput.

Fluxo de Trabalho Operacional:
1. Managed Feed Intake: Runofmine ore is directed via heavyduty apron feeder to the primary crusher, ensuring a consistent, chokefed load for optimal crushing action.
2. Redução de tamanho primário: The core crusher utilizes high inertia and optimized kinematics to reduce large lump ore (até 1,5m) to a manageable conveyorable size.
3. Escalpelamento Primário & Remoção de Multas: A downstream heavyduty scalper removes natural fines prior to secondary crushing, increasing circuit efficiency and reducing unnecessary wear.
4. Britagem Secundária & Closed Circuit Control (Opcional): A cone crusher module in closed circuit with a sizing screen allows precise control of final product gradation, typically to 50mm or 75mm for downstream milling.
5. Manuseio Integrado de Materiais: Plant design includes robust conveyor systems, transfer points with impact beds, and dust suppression integration for complete material flow management.

Escopo de aplicação: Designed for greenfield installations or major upgrades in magnetite (taconita) and hematite mining operations with annual capacity requirements from 5 para 25+ milhões de toneladas.

Limitações: Não é adequado para operações de baixa tonelagem (< 1 Mtpa) or as a tertiary/quartzite crushing unit without significant specification review.

3. RECURSOS PRINCIPAIS

Geometria de revestimento patenteada | Base Técnica: Análise de Elementos Finitos (FEA) & modelagem de desgaste | Benefício Operacional: Consegue uma gradação de produto mais consistente durante todo o ciclo de vida do liner, with reduced risk of bridging | Impacto do ROI: Até 15% longer liner life reduces direct parts cost and changeout downtime

Carga Inteligente & Sistema de controle de alimentação | Base Técnica: Realtime motor power & hydraulic pressure monitoring with automated feeder response | Benefício Operacional: Maintains optimal crusher cavity loading, preventing overload stalls and emptycavity wear | Impacto do ROI: Protege os componentes da unidade contra cargas de choque; dados de campo mostram um 712% redução no consumo específico de energia (kWh/tonelada)

Modular Plant Subframe Design | Base Técnica: Aparafusados, heavygauge steel modules with precisionmachined interfaces | Benefício Operacional: Enables faster onsite erection and future reconfiguration or relocation with minimal cutting/welding | Impacto do ROI: Can reduce civil works and installation time by an estimated 30%, acelerando o tempo de produção

Lubrificação Centralizada & Fluid Systems | Base Técnica: Singlepoint lubrication distribution blocks with monitoring points for all critical bearings | Benefício Operacional: Ensures correct lubrication intervals are met reliably, extending bearing service life in highdust environments | Impacto do ROI: Lowers manual maintenance labor hours by ~25% per shift and decreases bearing failure risk

HeavyDuty Dust Containment Skirting | Base Técnica: Multistage rubber skirting with adjustable tensioning on all conveyor transfers | Benefício Operacional: Dramatically reduces airborne dust at emission points, melhorando a segurança do local e a conformidade ambiental | Impacto do ROI: Lowers water consumption for suppression and reduces cleanup costs; minimizes risk of regulatory noncompliance penalties

Crusher Backing Material Integration | Base Técnica: Automated dispensing system for epoxy resin backing during liner installation | Benefício Operacional: Ensures complete cavity fill without air pockets, maximizing liner stability and energy transfer | Impacto do ROI: Eliminates premature liner failure due to improper backing, protecting major crusher body components

Plataformas de manutenção WalkIn | Base Técnica: Integrated, OSHAcompliant platforms with handrails around all major service points (crusher top shell, motor, feixes) | Operational Benefit Provides safe, direct access for inspection and component handling during planned maintenance| ROI Impact Reduces servicerelated safety incidents; improves maintenance efficiency by providing stable work areas

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Média) | Custom Iron Ore Crushing Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Vida útil do forro (Primary Mantle/Bowl) | ~1.2 Million Tonnes
Varia de acordo com a abrasividade do minério| ~1.5 Million Tonnes
Based on magnetite feed| +25% |
| Total Plant Availability (Tempo de execução agendado) | 9294%
Includes minor stops| >96%
Design target| +34 Pontos percentuais |
| Consumo Específico de Energia
(kWh por tonelada moída) Baseline Dependent
Varia de acordo com o projeto do circuito| Field data indicates reduction of
712% contra. nonoptimized equivalent systems.| Até 12% |
| Tempo médio entre falhas (MTBF)
for Major Components
~2，000 horas
Drive/motor/bearing assemblies| >2，500 horas
Design target based on load management| +25% |
| Tempo de inatividade planejado para manutenção
(per major liner change event)
4872 horas
Crew dependent|<36 hours target
Via modular liners & plataformas| 33% |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 2，500 acabar 8，000 toneladas por hora (tph)， depending on feed size， ore work index，and product size requirement.
Opções do britador primário: Trituradores giratórios (54Abertura de alimentação ”75”) ou britadores de mandíbula (60”x80”+). Selection based on required throughput， feed topology，e análise de fragmentação.
Impulsione a potência: Acionamentos de motores elétricos que variam de 450 kW para 1，200 kW，with Vbelt or direct drive configurations available。 Softstart systems standard。
Especificações de materiais：
Revestimentos do britador： Manganese steel alloy（14%18%）with optional chrome carbide overlay for extreme abrasion zones。
Aço Estrutural： Primary support structures use S355JR grade steel； highwear areas utilize AR400 abrasionresistant plate。
Conveyor Idlers： CEMA class E/F sealed bearings； impact idlers at loading zones。
Physical Dimensions （Modular）： Módulos projetados para dimensões padrão de contêineres de transporte。 Typical primary station footprint： ~30m L x 15m W x 20m H （variable）。
Faixa operacional ambiental：
Temperatura Ambiente： 30°C to +50°C （with appropriate lube oil/heater packages）。
Emissões de poeira： Designed to achieve <10 mg/Nm³ at containment points with integrated suppression。
Nível de ruído： Compliant with <85 dB(UM) at operator stations via acoustic enclosures。

6. CENÁRIOS DE APLICAÇÃO

Greenfield Magnetite Concentrator｜Challenge： A new mine required a primary crushing plant capable of processing highly abrasive taconite at 6，000 tph，with strict product sizing (250milímetros) for SAG mill feed。 The remote location demanded high reliability due to limited local maintenance support。｜Solução： A customized gyratory crusherbased plant featuring our intelligent load control system， extendedlife liner package，and fully walkin maintenance modules was installed。 All lubrication and electrical cabinets were housed in heated enclosures。｜Resultados： A planta atingiu a capacidade nominal duas semanas após o comissionamento。 A vida útil do revestimento excedeu as projeções em 8%， alcançando mais 1。6 milhões de toneladas por conjunto。 Availability has averaged 96。7% over the first three years of operation。

Hematite Processing Plant Upgrade｜Challenge An existing hematite operation experienced chronic bottlenecks due to an aging jaw crusher plant suffering from frequent bearing failures and poor throughput consistency (<2，200 tph)，limiting downstream beneficiation output。｜Solution We replaced the existing unit with a customized modular jaw plant featuring the centralized greasing system，heavyduty skirting，and an optimized feeder/crusher interface geometry tailored to the specific ore characteristics。｜Results Throughput increased consistently above design rate of 2，800 tph。 Bearingrelated unscheduled downtime was eliminated in the first year postinstallation。 Product size distribution became markedly more uniform (+/10%) improving downstream screening efficiency。

7． CONSIDERAÇÕES COMERCIAIS

Our approach is based on providing transparent value aligned with your production targets。

Níveis de preços
• Base Plant Configuration Includes core crusher motor feeders basic discharge conveyor structural supports walkways ladders
• Enhanced Configuration Adds intelligent control system dust suppression package premium liner options automated lubrication
• Turnkey Project Package Full engineering procurement construction management EPC/M including foundations electrical reticulation commissioning spares package

Recursos opcionais
• OnBoard Hydraulic Power Unit For setting adjustment/clearing
• Rock Breaker Boom System For oversize breaking at grizzly
• Advanced Predictive Monitoring Vibration temperature sensors linked to SCADA
• Modular Secondary/Tertiary Crushing Stage For future expansion

Pacotes de serviços
• Planned Maintenance Agreements Scheduled inspections parts supply labor rates defined upfront
• Performance Guarantee Contracts Uptime availability或throughput guarantees supported by remote monitoring
• Liner Service Programs Fixedcostpertonne agreements covering all wear parts

Opções de financiamento
We work with accredited partners to offer equipment leasing capital loans以及operational expenditure OpEx models where payment is tied directlyto verified production tonnage。

8． Perguntas frequentes

Q What level of site preparation is required prior delivery？
A Our modular plants require prepared concrete foundations designed specificallyfor your soil conditions We provide full foundation drawings anchor bolt locations as partof basic engineering Minimal field welding should be required。

Q How does this solution integrate into my existing control room SCADA system？
A The plant control panel can be supplied asa standalone PLCbased systemor configuredto communicate via industrystandard protocols Modbus TCP/IP Profibus etc allowing full visibilityand control fromyour central facility。

Q Are performance guarantees offered？
A Yes subjectto mutually agreedupon feed material specifications we can contractually guarantee rated throughput capacity final product P80 sizing以及specific energy consumption targets。

Q What isthe typical lead timefrom order placementto commissioning？
A For standard configurations lead times range between914 months dependingon current manufacturingload Complex customizations may extendthis timeframe Detailed project schedules are provided upon initial technical review。

Q How do you address ongoing technical supportfor remote sites？
A We offer tiered support including24/7 remote diagnostics access trained regional service technicians以及comprehensive documentation Parts are strategically warehousedin key mining regions globallyto expedite delivery。

Q Can this plant be relocatedin future？
A Yes themodular bolted subframe designis specifically engineeredfor disassembly relocation andreassembly Minimally destructive techniquesare used preserving structural integrity Relocation feasibility studiesare availableas separate consultancy service。

Q What trainingis providedfor our operationsand maintenance teams？
A Comprehensive trainingis included covering normal operation shutdown procedures routine maintenance tasks troubleshooting We provide both classroom sessionsat our facility handson training during commissioningat yours alongwith detailed operational manuals