1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo suas margens de produção agregadas? Para gerentes de fábrica e empreiteiros de engenharia, os principais desafios na britagem primária geralmente se concentram em três áreas críticas:

Tempo de inatividade não programado: Mudanças freqüentes de revestimento, falhas mecânicas inesperadas, and clogged chambers halt your entire processing line. Industry data indicates that each hour of crusher downtime can cost over $10,000 em produção e trabalho perdidos.
Aumento dos custos operacionais: Are you constantly battling high energy consumption per ton of processed material, coupled with the escalating expense and frequency of wear part replacements?
Saída inconsistente & Qualidade: Fluctuations in feed size or hardness resulting in poor product shape, uneven gradation, and increased recirculating load that bottlenecks secondary crushers and screens.

How do you achieve reliable throughput with predictable maintenance windows and lower costperton? The solution requires a robust foundation: a primary crushing station engineered for durability and efficiency.

2. VISÃO GERAL DO PRODUTO: ODM HeavyDuty Primary Jaw Crusher Plant

This product is a stationary or semimobile primary crushing plant centered on a heavyduty jaw crusher. It is designed as the first stage in mineral processing and aggregate production to reduce runofmine ore or blasted quarry rock to a manageable size for downstream conveying and processing.

Fluxo de Trabalho Operacional:
1. Alimentar: Dump trucks or loaders deposit raw material into a reinforced hopper.
2. Pré-triagem (Opcional): A grizzly feeder removes fines to bypass the crusher, melhorando a eficiência e reduzindo o desgaste.
3. Britagem Primária: The core jaw crusher utilizes compressive force to break large stones between a fixed and a reciprocating jaw plate.
4. Descarga: Crushed material is discharged onto a main conveyor belt for transport to the next stage of the circuit.

Escopo de aplicação & Limitações:
Escopo: Ideal para mineração de rocha dura (granito, basalto), quarrying for aggregate, and construction waste recycling with reinforced concrete. Suited for hightonnage primary reduction.
Limitações: Not designed for abrasive metal ores better suited to gyratory crushers at very high capacities (>3000 tph). Requires prepared feed; maximum lump size is limited by crusher inlet dimensions.

3. RECURSOS PRINCIPAIS

Câmara de britagem profunda & Cinemática Otimizada | Base Técnica: Increased nip angle and longer stroke | Benefício Operacional: Enables higher capacity reduction in a single pass, melhorando o rendimento em até 15% em comparação com designs convencionais | Impacto do ROI: Higher output per operating hour directly lowers fixed cost allocation per ton.

Estrutura principal fabricada para serviços pesados | Base Técnica: Construção em chapa de aço com alívio de tensão e nervuras reforçadas | Benefício Operacional: Fornece durabilidade excepcional contra cargas de choque de materiais não trituráveis, minimizando a fadiga da estrutura e o risco de falha catastrófica | Impacto do ROI: Extends total plant service life, protects major capital investment.

Ajuste Hidráulico & Sistema de compensação | Base Técnica: Integrated hydraulic cylinders for toggle tension and chamber clearing | Benefício Operacional: Allows operators to adjust CSS quickly under load and automatically reverse the jaw to clear blockages without manual intervention | Impacto do ROI: Reduces adjustment time by 70% and eliminates hours of dangerous manual clearing labor per incident.

Revestimentos de desgaste BoltOn & Mordentes Modulares | Base Técnica: Symmetrical design and standardized mounting hardware | Benefício Operacional: Enables rotation/replacement of wear parts from one side of the crusher. Reduces liner inventory requirements through interchangeability | Impacto do ROI: Reduz o tempo de inatividade programada para manutenção em até 40% and lowers spare part holding costs.

Interface de automação baseada em PLC | Base Técnica: Centralized control with sensors for power draw, CSS monitoring, e temperatura do rolamento | Benefício Operacional: Provides realtime operational data for predictive maintenance scheduling. Allows remote monitoring of key performance parameters | Impacto do ROI: Prevents unplanned stops through condition monitoring; optimizes performance settings for variable feed conditions.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | ODM Jaw Crusher Plant Solution | Vantagem documentada |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | 8590% (incluindo manutenção programada) |> 93% disponibilidade desejada| +58% melhoria |
| Use a vida (Mn13/18 Jaw Plates) on Granite| 120,000 150,000 toneladas| 180,000 220,000 toneladas| +4050% melhoria |
| Consumo de Energia por Tonelada Moída| Varia de acordo com o tipo de rocha; linha de base = 100%| Optimized kinematics reduce specific energy demand| Até 12% redução |
| Total Maintenance Hours per Year (Agendado)| ~250300 hours| ~160200 hours|<30% redução |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade da gama de modelos: 150 1,200 toneladas por hora (TPH), dependendo do material de alimentação e da configuração do lado fechado (CSS).
Abertura de alimentação do britador: De 900 mm x 600 mm até 1500 mm x 1200 mm.
Requisitos de energia: Motor principal do britador de 75 kW para 250 kW. Total plant power including feeders and conveyors specified per configuration.
Especificações de materiais: Main frame constructed from Q345B steel plate; jaw dies available in Mn13Cr2, Mn18Cr2, or custom martensitic alloys; Eixo forjado em liga de aço de alta resistência (42CrMo).
Dimensões Físicas (Typical Stationary Plant): Length ~18m; Width ~6m; Altura ~7m (varies significantly with model).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Padrão do sistema de supressão de poeira; noise encapsulation optional.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Desafio: An existing quarry needed to increase primary output by over 60%. The existing plant suffered from excessive vibrationrelated cracks in the frame structure leading to frequent unscheduled repairs.
Solução: Implementation of an ODM heavyduty jaw crusher plant with a reinforced fabricated frame design rated at 650 TPH.
Resultados: After two years of operation at full capacity:
94% operational availability achieved.
0 structural integrity issues reported.
Costperton reduced by an estimated $1.15 due to higher throughput efficiency.

LargeScale Infrastructure Concrete Recycling

Desafio: A contractor required onsite primary crushing of demolished concrete with high rebar content at multiple locations within an urban environment requiring rapid setup/teardown.
Solução: Deployment of a semimobile ODM jaw crusher plant variant equipped with an overband magnet for metal extraction.
Resultados:
95% pure aggregate produced onsite for reuse as road base.
30minute hydraulic clearing system successfully managed multiple rebar jamming events without major delay.
80% reduction in trucking costs associated with hauling demolition waste offsite.

7. CONSIDERAÇÕES COMERCIAIS

ODM provides tailored commercial solutions based on project scope:

Níveis de preços: Com base na classificação de capacidade (por exemplo, 500 TPH) level of automation integration included as standard or optional features such as dust suppression systems noise enclosures advanced condition monitoring packages extended warranty coverage beyond standard terms financing options available through partner institutions including leasetoown structures which can preserve capital expenditure budgets installation commissioning supervision packages are offered separately or bundled

8.Perguntas frequentes

1.P:What is the lead time for delivery?
A.For standard models lead time ranges from weeks depending on current production schedule Custom configurations may require additional engineering time

2.P:What are typical installation requirements?
A.A prepared concrete foundation plan is provided along with full dimensional drawings Electrical connection specifications are detailed well in advance

3.P:What level of technical support is provided during commissioning?
A.Commissioning support includes supervision by factorytrained engineers ensuring proper setup initial calibration operator training

4.P:Quais são as condições de pagamento?
A.Terms are typically structured around milestones such as order confirmation preshipment inspection final acceptance after commissioning

5.P:What factors most influence wear part life?
A.Primary factors include feed material abrasiveness compressive strength feed size distribution versus CSS setting consistent feeding practices