1. ABERTURA ACIONADA POR PAINPOINT

Are escalating operational costs and unpredictable downtime eroding your quarry’s profitability? Managing a stone quarry crushing plant presents persistent challenges that directly impact your bottom line. Os pontos problemáticos comuns incluem:
Tempo de inatividade excessivo para manutenção: Mudanças freqüentes de revestimento, falhas de rolamento, and unexpected breakdowns halt production. Industry data indicates unplanned downtime can cost over $10,000 por hora em perda de produção e trabalho.
Gradação inconsistente do produto: Fluctuations in feed material or crusher performance lead to offspec aggregate, resultando na rejeição do produto, custos de reciclagem, e clientes insatisfeitos.
Alto consumo de energia: Câmaras de britagem e acionamentos ineficientes consomem energia excessiva, which often represents 4050% of a plant’s operational expenditure.
Degradação rápida de peças de desgaste: Abrasive stone varieties cause premature wear on liners, martelos, e mandíbulas, leading to high consumable costs and frequent production stops.
Flexibilidade Limitada & Escalabilidade: Fixed plants struggle to adapt to changing market demands for different aggregate sizes or increased throughput.

Is your current setup equipped to minimize these risks? The right primary crushing station is not just a machine purchase; it’s a strategic investment in plantwide stability and efficiency.

2. VISÃO GERAL DO PRODUTO: PRIMARY JAW CRUSHING STATION

A Primary Jaw Crushing Station is a heavyduty, stationary or semimobile unit designed for the first reduction of blasted quarry rock into manageable sizes for further processing. It forms the critical foundation of any aggregate production line.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Caminhões basculantes ou carregadeiras depositam grandes (até 1,5m) blasted rock into a rugged vibrating grizzly feeder (VGF VGF).
2. Pré-triagem & Ignorar: The VGF separates fines from the primary feed, directing undersize material to a bypass conveyor to reduce crusher load and wear.
3. Redução Primária: Oversize rock is fed into the jaw crusher chamber, where a fixed jaw and a moving jaw exert immense compressive force to break the stone.
4. Descarga & Transporte: Crushed material is discharged at a reduced size (normalmente 150250 mm) em um transportador principal de produto para transporte para britagem secundária ou armazenamento.

Escopo de aplicação & Limitações:
Escopo: Ideal para difícil, materiais abrasivos como granito, basalto, and trap rock. Suited for hightonnage quarry primary crushing applications.
Limitações: Não é ideal para macio, nonabrasive stone (where impact crushers may be preferred) or as a standalone unit for producing final spec aggregate without secondary/tertiary stages.

3. RECURSOS PRINCIPAIS

Alimentador Grizzly Vibratório para Serviço Pesado (VGF VGF) | Base Técnica: Highinertia vibratory mechanism with adjustable grizzly bars | Benefício Operacional: Remove finos antes da britagem, reduces crusher load and wear, prevents choking | Impacto do ROI: Extends crusher liner life by up to 20%, reduces energy consumption per ton

Ajuste CSS baseado em cunha | Base Técnica: Hydraulically assisted wedge system for setting the closed side setting (CSS) | Benefício Operacional: Allows quick and safe adjustment of product top size without manual shims, even while empty | Impacto do ROI: Reduces CSS change time from hours to minutes, maximizing uptime during product changeovers

QuarrySpecific Jaw Die Profiles | Base Técnica: CADoptimized tooth profiles based on feed material analysis (por exemplo, MTM for abrasive rock) | Benefício Operacional: Improves nip angle and material flow, reducing slabby product and increasing throughput | Impacto do ROI: Entrega até 10% higher throughput with same power draw versus standard profiles

Base de motor integrada & Protetor de cinto | Base Técnica: Unified base frame for crusher, motor, e roldanas com proteção perimetral completa | Benefício Operacional: Simplifica o alinhamento da instalação, melhora a conformidade com a segurança do local (OSHA/CE), protege os componentes da unidade | Impacto do ROI: Cuts installation time by ~30%, reduces risk of costly safety incidents

Pontos de lubrificação centralizados & Portas de monitoramento de condições | Base Técnica: Manifolded lubrication lines accessible from ground level with ports for sensor integration | Benefício Operacional: Enables safer routine maintenance and realtime monitoring of bearing health (temperatura/vibração) | Impacto do ROI: Facilitates predictive maintenance scheduling, evitando falhas catastróficas nos rolamentos que causam tempo de inatividade prolongado

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Primary Jaw Crushing Station Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | 8590% due to liner changes & ajustes| >92% with hydraulic CSS & quickwear systems| +35% horas mais produtivas anualmente |
| Tonnage per kWhr| Varia muito; linha de base = 100%| Câmara otimizada & projeto de acionamento| +812% eficiência energética melhorada |
| Vida útil do forro (Rocha Abrasiva)| ~150k tons per set| Materialspecific profiles & even wear design| +1525% vida útil mais longa |
| Configurar / Tempo de reconfiguração| Multiple shifts with cranes & trabalho manual| Integrated chassis with preassembled components| 40% faster site commissioning |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: 400 1,800 MTPH (depende do material de feed e CSS)
Abertura de alimentação do britador: Up to 60” x 80” (1,500mm x 2,000mm)
Impulsione a potência: 150 400 kW electric motor with Vbelt transmission
Especificações de materiais: Fabricado em chapa de aço de alta resistência; Jaw dies available in Mn18%, Mn22%, ou ligas compostas; Shaft forged from highstrength alloy steel.
Dimensões Físicas (Estacionário): Aprox.. Comprimento: 12m – 18m; Largura: 4m – 6m; Altura: 5m – 7m (incluindo alimentador).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; Dustsealed bearings; Weather protection standard.

6. CENÁRIOS DE APLICAÇÃO

Expansão da Pedreira de Granito | Desafio: An existing quarry needed to increase primary throughput by 35% without expanding its footprint or primary feed conveyor infrastructure. The legacy crusher could not achieve higher capacity without excessive wear and energy cost.| Solução: Implementation of a new Primary Jaw Crushing Station featuring a deeper “ST” chamber design optimized for granite and an oversized VGF to improve feed kinetics.| Resultados: Achieved the targeted 35% throughput increase while reducing specific energy consumption by 9%. Wear life on stationary jaw liners improved by approximately three weeks per set under equivalent tonnage.

MultiStage Plant Modernization | Desafio:A contractor operating multiple sites faced high mobilization costs and variable product quality due to aging,c disparate primary units.| Solução:S tandardization on modular Primary Jaw Crushing Stations with identical control interfacesand wear parts across all sites.| Resultados:R educed spare parts inventory by25%,cut operator training time,and improved average plant availabilityby4% through familiarizationand interchangeable components.

7. CONSIDERAÇÕES COMERCIAIS

Níveis de preços: Capital cost varies based on sizeand configuration.Equipment typically falls into three tiers:
Dever Padrão: For lowerabrasion materials (<600 MTPH).
Serviço Pesado: Fullfeaturedfor hard rock quarries(600–1 ,200 MTPH).
Serviço Extra Pesado / Modular: For max throughput (>1 ,200 MTPH)and fast relocation requirements.
Recursos opcionais& Atualizações: Options include automated lubrication systems,kits de supressão de poeira,tramp iron relief hydraulics,and advanced condition monitoring packageswith remote connectivity.
Pacotes de serviços: Comprehensive support plans are available,rangingfrom basic preventive maintenance schedules too fully comprehensive partsandlabor agreementscoveringwear partsand scheduled overhauls,predictingtotalcostpertoncrushed.
Opções de financiamento : Flexible commercial structures are offered including capital lease ,arrendamento operacional ,or rentaltoown programs designedto alignwithmineplan cashflow projections .

8.Perguntas frequentes

P:What factors determine whether we needa stationaryor modular/semimobileprimary station?
UM:The decision hinges on site lifespanand flexibility requirements .Stationary plants offer maximum robustnessfor longlife quarries (>10 anos).Modular stationson trailer assemblies provide significant advantagesfor multisite contractorsor quarrieswith phased developmentplans ,enabling relocation between pits .

Q.How do we ensure this crusheris compatiblewith our existing secondary circuitand conveyors?
A.Detailed reviewof your required discharge setting(product top size)and calculated throughputis essential .Our engineering team will modelthe entire flowbasedon your feedmaterial analysis tomatchcapacityand ensureproper chokefeedconditionsfor downstream equipment .

Q.What isthe expected operational impacton our workforce?
A.Trainingis provided .Your operatorswill benefitfrom simplified ,saferproceduresfor CSS adjustmentand routine greasing .The reduced frequencyof liner changesalso lowers exposureto manual handlingrisksinside the crusher cavity .

Q.Are wear parts readily available,and whatarethe typicalcosts?
A.Wear parts(mandíbula morre ,placas de bochecha )are stockedregionally undera guaranteedavailability program .Costpertonvariesby material abrasiveness ;we providea detailedwear costprojectionbasedon your specific rock analysis duringthe quotation process .

Q.What commercial termsare typicalfor suchcapital equipment?
A.Terms generally involvea significantdown paymentupon order,followedby progress paymentsalignedwithmajor manufacturing milestones ,with balance due upon shipment .The specificsare tailoredto project scaleand customer history .

Q.What does implementationinvolvefrom deliveryto commissioning?
A.We providefoundation drawingsin advance .Delivery includessupervisionof offloadingand positioning .Full scope erection ,mechanical alignment ,conexão elétrica ,and commissioningby certified field service engineersis availableas partofa turnkey package .

Q.Can you assistwith performance guarantees?
A.Y es.Performance guaranteesfor throughput ,gradação do produto ,consumo de energia,and wear partlife are providedin writingbasedon agreedfeedmaterial characteristicsandsite conditions .