H1: ODM Stationary Crushing & Planta de triagem: Projetado para máximo tempo de atividade e tonelagem

1. Addressing Your Core Operational Challenges in Aggregate Production

Managing a fixed crushing site presents distinct, desafios dispendiosos. Downtime isn't just lost production; it's missed contracts and eroding margins. Você está enfrentando:
Paradas não planejadas: Falhas de rolamento, bloqueios do britador, and conveyor issues can halt your entire line. Every hour of downtime can cost thousands in lost revenue and idle labor.
Produto final inconsistente: Fluctuations in feed material or improper calibration lead to offspec aggregate, resultando na rejeição do produto, custos de reciclagem, e relacionamentos com clientes prejudicados.
Alta complexidade de manutenção: Disjointed equipment from multiple suppliers creates a spare parts nightmare and extends maintenance windows, straining your operational budget.
Fluxo de materiais ineficiente: Bottlenecks between crushing stages or screening units cap your plant's true capacity, forcing you to run longer hours at higher cost per ton.
Aumento dos custos operacionais: Unidades energeticamente ineficientes, consumo excessivo de peças de desgaste, and high manual labor for monitoring directly reduce your profitability per cubic meter.

The question is not just how to crush rock, but how to build a reliable, predictable production asset. The solution lies in a fully integrated system designed from the ground up for synchronized performance.

2. Visão geral do produto: The Integrated Stationary Crushing & Planta de triagem

The ODM Stationary Crushing & Screening Plant is a complete, hardwired processing circuit engineered for highvolume aggregate production in quarrying and mining applications. It transforms raw feed (0800milímetros) into precisely graded final products (por exemplo, 05mm areia, 520mm agregado).

Fluxo de Trabalho Operacional:
1. Alimentação Primária & Esmagamento: Dump trucks feed a vibrating grizzly feeder which removes fines and directs oversize to a robust primary jaw crusher for initial size reduction.
2. Processamento Intermediário & Triagem: Crushed material is conveyed to a secondary cone crusher for further reduction. Output is then routed to a multideck vibrating screen for classification.
3. Classificação de produtos & Estoque: Onspec material from each screen deck is conveyed to designated stockpiles. Oversize is recirculated back to the appropriate crusher in a closedcircuit loop.

Escopo de aplicação: Ideal for hightonnage production of aggregates for concrete, asfalto, and road base. Adequado para processamento de granito, basalto, calcário, and other abrasive ores.

Limitações: This is a fixedinstallation solution requiring foundational concrete works and grid power connection. Não foi projetado para realocação frequente.

3. Recursos principais: Engenharia atende ao ROI operacional

Modular Structural Frame | Base Técnica: Pré-fabricado, hightensile steel sections with machined connection points | Benefício Operacional: Permite mais rápido, more precise onsite installation with reduced crane time and foundation work | Impacto do ROI: Cuts installation timeline by up to 30%, reducing timetorevenue.

Sistema de controle PLC centralizado | Base Técnica: Controlador lógico programável com interface homem-máquina (IHM) painel | Benefício Operacional: Allows singleoperator monitoring and control of the entire flow from feeder to final conveyor; fornece alertas de diagnóstico | Impacto do ROI: Reduces labor requirements by approximately 1 FTE per shift while improving response time to anomalies.

HeavyDuty Vibrating Screen with QuickDeck Change | Base Técnica: Rubbermounted screen box with tensioned wedgewire or polyurethane panels | Benefício Operacional: Minimizes vibration transfer to structure; allows screen media replacement in hours vs. dias | Impacto do ROI: Increases annual availability by ~2% and reduces maintenance labor costs.

Crusher Cavity Optimization | Base Técnica: Computeraided design of crushing chamber geometry matched to expected feed material | Benefício Operacional: Maximizes reduction ratio per pass, improves product shape (cubicidade), and promotes even wear liner utilization | Impacto do ROI: Boosts throughput by 515% while extending wear part life cycles.

Supressão de poeira & Sistema de Contenção | Base Técnica: Strategically placed spray nozzles at transfer points with encapsulation skirts | Benefício Operacional: Mantém a conformidade regulatória para emissões de partículas; protects bearings and motors from dust ingress | Impacto do ROI: Avoids regulatory fines and reduces premature bearing failures by an estimated 40%.

Layered Walkways & Plataformas de Manutenção | Base Técnica: Full perimeter access with safety handrails integrated into the plant design | Benefício Operacional: Enables safe visual inspections, routine greasing, and component servicing without specialized scaffolding | Impacto do ROI: Promotes proactive maintenance culture; reduces risk of safety incidents and associated downtime/costs.

4. Vantagens Competitivas: Ganhos de desempenho quantificáveis

| Métrica de desempenho | Referência padrão da indústria | ODM Stationary Plant Solution | Vantagem documentada |
| : | : | : | : |
| Disponibilidade de planta (Tempo de execução agendado) | 9092% | 9496%| +4% Melhoria |
| Consumo de Energia por Tonelada Processada| Varia de acordo com o tipo de rocha| Optimized motor loads & unidades eficientes| Até 12% Redução |
| Custo da peça de desgaste por tonelada métrica| $0.85 $1.10 USD| Matched chamber design & seleção de liga| 1520% Redução |
| Instalação & Tempo de comissionamento| 810 Semanas (from foundation)| Modular frame & unidades pré-montadas| ~30% Faster (67 Semanas)|
| Required Operating Labor per Shift| 34 Personnel| Centralized PLC control system| Reduzido em 1 Operator |

5. Especificações Técnicas

Faixa de capacidade de projeto: 200 800 TPH (configurable based on model).
Requisito de energia primária: 400V/50Hz ou 480V/60Hz; Potência Total Instalada: 350kW 800kW.
Principais especificações de materiais:
Revestimentos do britador: Aço Manganês (14%,18%,22%) or Chrome Iron Alloy options.
Plataformas de tela:Tensioned Polyurethane or HighCarbon Steel Wire Mesh.
Correia transportadora:Synthetic Fabric Ply (EP630/3) with minimum 12mm top cover.
Aço Estrutural:S355JR grade with hotdip galvanized finish on walkways.
Typical Physical Footprint (for a 350TPH plant): ~35m (eu) x 22m (C) x 15m (H).
Faixa operacional ambiental: Ambient temperature 20°C to +45°C; níveis de emissão de poeira em conformidade com <10mg/Nm³ standards when used with suppression system.

6. Cenários de aplicação

Projeto de Expansão de Pedreira de Granito

Desafio:A quarry needed to increase output by over 60% but had limited space for plant expansion within their existing lease boundary.Solution:Um compacto,OEMdesigned threestage crushing circuit was installed,fitting into the footprint of an older twostage plant.The design included a large primary jaw crusher followed by two secondary cone crushers in parallel configuration feeding shared screens.This allowed higher throughput without increasing land use.The centralized control system was integrated into their existing site office via fiber optic cable.The new layout reduced internal haulage distances significantly.Retrofitted spray systems kept dust under control during blasting operations near residential areas.Finally,the modular construction allowed commissioning during planned seasonal shutdown minimizing disruption.Financing was secured through an equipment lease agreement preserving capital for other site improvements.Regular service visits ensured optimal performance throughout the warranty period leading them purchase an extended coverage plan.This holistic approach transformed their operational constraints into competitive advantage securing several large infrastructure contracts previously out reach due capacity limitations

Processamento de calcário para alimentação de fábrica de cimento

Desafio:A cement producer required consistent 25mm feed for their raw mill,but variations in quarry moisture content caused frequent clogging in their existing impact crusher.Solution:The implementation featured a primary jaw crusher followed by a heavyduty cone crusher equipped with automated setting regulation.Air cannons were installed at key hopper points,and conveyor skirts were extended.The PLC system was programmed to adjust feeder speed based on crusher motor load.Field data after six months showed clogging events reduced by over95%.Product consistency improved dramatically meeting the 25mm spec99.%of the time.This reliability allowed the cement kiln department optimize their own processes knowing raw material supply would be uninterrupted

Reciclagem de Projetos de Infraestrutura Urbana

Desafio:A major road construction project mandated onsite recycling of demolished concrete to reduce truck traffic environmental impact but faced strict noise dust regulations tight urban site.Solution:A semimobile configuration was deployed featuring extensive acoustic enclosures around all major noise sources like crushers screens fully enclosed conveyors waterbased dust suppression systems every transfer point.The plant processed over500000tons recycled concrete aggregate meeting all stringent local environmental standards avoiding thousands truck movements city center

Considerações Comerciais

Pricing is structured around plant capacity,customization level,and chosen component brands(e.g.,crusher motor manufacturer).We offer three primary tiers:

1.Camada de configuração básica:Covers core functionality standard components proven reliability suitable budgetconscious operations seeking essential performance.Pricing typically ranges from$750000to$1million USD depending capacity

2.Nível de desempenho(Recomendado):Includes features like centralized PLC automation premium wear liners enhanced dust suppression walkways platforms.Pricing typically ranges from$ million$ million USD

3.Nível Premium pronto para uso:Fully customized solution including advanced predictive monitoring sensors extended warranty comprehensive operator training package civil engineering drawings support.Pricing determined specific project scope

Atualizações de recursos opcionais:
Advanced vibration monitoring sensors critical bearings
Sistemas de lubrificação automatizados
Overband magnetic separator ferrous metal removal
Additional finished product conveyor stackers
Kit inicial de peças de reposição

Pacotes de suporte de serviço:
Standard Warranty months parts labor excluding wear items
Extended Coverage Plans years available purchase
Annual Maintenance Contracts include scheduled inspections priority technical support discounted spare parts
OnDemand Field Service Technician dispatch available global network partners

Opções de financiamento:
We work accredited financial partners offer:
Equipment leasing structures preserve working capital
Term loans competitive rates project financing
RentaltoOwn programs lower initial commitment

Seção de perguntas frequentes

E se a dureza do meu material de alimentação mudar frequentemente?
Our cone crushers recommended Performance Tier feature hydraulic adjustment CSS clearing allow quick adaptation different rock characteristics without stopping process ensuring consistent output quality varying conditions

How does this integrate existing equipment like my primary excavator loaders?
Plants designed flexible feeding arrangements accommodate different loading methods We provide interface specifications hopper heights capacities ensure compatibility your current loading fleet minimizing integration issues

Qual é o prazo de entrega típico do comissionamento?
For standard configurations lead time typically weeks exworks following deposit receipt Site commissioning supervised our engineers requires approximately weeks depending complexity local readiness

As peças sobressalentes estão prontamente disponíveis em todo o mundo??
Yes maintain strategic inventory critical components partner global logistics providers ensure expedited shipping Additionally provide detailed part numbers crossreferences equivalent items facilitate local sourcing noncritical parts where appropriate

Você oferece treinamento de operador?
Yes comprehensive training included Turnkey Tier optional others covers normal operation routine maintenance troubleshooting safety procedures Training conducted both our facility yours ensure competence confidence your team