ROHS Compliant Iron Ore Crushing Plant | Engineered for Sustainable, HighYield Mineral Processing

1. PAINPOINT DRIVEN OPENING

Managing an iron ore processing operation involves navigating a complex set of efficiency, environmental, and maintenance challenges. Are you experiencing:
Unplanned Downtime & Contamination: Component failures from nonspecialized wear parts lead to costly stoppages. More critically, standard machinery can introduce restricted hazardous substances (like lead, cadmium, mercury) into your material stream, jeopardizing product purity and RoHS compliance for downstream steelmakers.
Inefficient Throughput & High Energy Cost: Inconsistent feed size reduction creates bottlenecks, forcing secondary and tertiary crushers to work harder. This directly increases power consumption per ton of processed ore, eroding profit margins.
Excessive Maintenance Labor & Parts Inventory: Frequent liner changes, bearing failures, and unplanned repairs demand significant technician hours and require a large inventory of spare parts, tying up capital and increasing total operational cost.
Environmental Compliance Risk: As global supply chains mandate stricter material declarations (RoHS, REACH), noncompliant equipment can be a source of contamination, risking contract violations and reputational damage.

The central question for plant managers is: how can you achieve reliable throughput while futureproofing your operation against stringent environmental material regulations?

2. PRODUCT OVERVIEW

A RoHS Compliant Iron Ore Crushing Plant is a configured system of primary, secondary, and tertiary crushers—such as jaw crushers, gyratory crushers, and cone crushers—along with screens and conveyors, where all wear parts, lubricants, seals, and electrical components are certified free of Restricted Hazardous Substances per Directive 2011/65/EU.

Operational Workflow:
1. Primary Crushing: ROM (RunofMine) iron ore is reduced to <200mm by a RoHScompliant jaw or gyratory crusher with certified manganese steel jaws/liners.
2. Screening & Secondary Crushing: Oversize material is routed to a cone crusher for further reduction. All screen meshes and crusher liners in the contact path are manufactured from compliant alloys.
3. Tertiary Crushing & Final Sizing: For specific pellet feed or sinter feed requirements, additional crushing stages ensure precise particle size distribution using compliant vertical shaft impactors (VSIs) or fine cone crushers.

Application Scope: Ideal for greenfield projects or retrofits supplying the international steel industry where RoHS/REACH material declarations are required. Suitable for magnetite, hematite, and taconite ores.

Limitations: Maximum feed size and throughput are determined by the specific plant configuration. Not designed for processing materials outside typical iron ore abrasion indices without specific liner customization.

3. CORE FEATURES

Certified Wear Part Composition | Technical Basis: Metallurgical alloy control & traceability | Operational Benefit: Guarantees crushed ore remains free of Pb, Cd, Hg, Cr(VI), PBBs/PBDEs contaminants | ROI Impact: Eliminates risk of batch rejection by compliancesensitive buyers; protects premium product pricing.

Optimized Cavity Design | Technical Basis: DEM (Discrete Element Modeling) simulation for ore flow and compression | Operational Benefit: Achieves desired reduction ratio with fewer crushing stages; produces more consistent product cubicity | ROI Impact: Reduces system energy draw by up to 15% and lowers wear on downstream equipment.

Centralized Greasing & Filtration System | Technical Basis: Automated lubrication with highefficiency particulate filtration | Operational Benefit: Extends bearing life in dusty environments; ensures only compliant greases are used systemwide | ROI Impact: Cuts bearing replacement costs by an average of 30% and reduces manual maintenance points.

PLCIntegrated Tramp Metal Protection | Technical Basis: Hydraulic release or clearing systems paired with metal detectors | Operational Benefit: Prevents catastrophic damage from digger teeth or drill bits; minimizes unplanned downtime events | ROI Impact: Field data shows a >90% reduction in major component damage from tramp metal incidents.

Modular Component Design | Technical Basis: Standardized subassembly interfaces for key wear components | Operational Benefit: Enables faster liner changes and component swaps during planned maintenance windows | ROI Impact: Reduces mean time to repair (MTTR) by approximately 25%, increasing plant availability.

Dedicated Compliance Documentation Package | Technical Basis: Full material traceability from supplier mill certificates to final assembly | Operational Benefit: Provides auditable proof of RoHS compliance for your entire customer chain | ROI Impact: Streamlines the procurement process for certified steel mills; strengthens supply chain position.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Equipment | RoHS Compliant Iron Ore Crushing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Compliance Assurance| Selfdeclared; limited part traceability| Full material certification for all contactpath components| Risk Mitigation (100% documented compliance) |
| Specific Energy Consumption| Varies widely; often suboptimized| Systemoptimized cavities & drives| Efficiency Gain (1015% reduction kWh/ton) |
| Mean Time Between Failure (MTBF)| Standard manganese liners & bearings| Certified alloys + optimized lubrication| Uptime Increase (2035% longer MTBF) |
| Product Contamination Risk| Possible from wear part degradation| Controlled via certified metallurgy| Quality Improvement (Eliminates regulated substance risk) |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 500 to 3,000+ tonnes per hour (TPH).
Power Requirements: Dependent on configuration; primary crushing stage typically requires 150450 kW motors. Total installed power available from 800 kW to 5 MW.
Material Specifications: All wearfacing components (liners mantles concaves jaw plates screen decks) use RoHScompliant highstrength manganese or chromium steel alloys. Electrical components meet RoHS Directive standards.
Physical Dimensions: Modular designs tailored to site layout. Primary station footprint typically ranges from 15m x 8m to 25m x 12m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust suppression systems are integrated as standard.

6. APPLICATION SCENARIOS

International Steel Mill Supply Chain

Challenge: A European pellet plant mandated all feed suppliers provide full RoHS material declarations. A mining operator’s existing crushing circuit could not guarantee the absence of restricted substances in worn liner material.
Solution: Retrofit of tertiary cone crushers with a fully certified RoHS Compliant Iron Ore Crushing Plant package for the final crushing stage.
Results: The operator secured a longterm premium supply contract after providing full compliance documentation. Product testing confirmed zero introduced contaminants.

HighAbrasion Taconite Processing

Challenge: A North American taconite processor faced high energy costs and excessive maintenance downtime across three crushing lines.
Solution: Replacement of two secondary crushers with models featuring DEMoptimized cavities and a centralized automated lubrication system as part of a compliant plant upgrade.
Results: Annual energy consumption reduced by 12%. Maintenance intervals extended by 28%, freeing up an estimated 350 laborhours per line annually.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Capital expenditure is structured around throughput capacity and automation level.
Base System: Primary + Secondary crushing with basic controls.
Optimized System: Includes tertiary crushing advanced PLC control dust suppression (~2030% premium).
Turnkey System: Full design civil works installation commissioning (~4060% premium).
Optional Features: Advanced predictive monitoring sensors remote operational diagnostics automated wear measurement systems rubberlined feed hoppers for noise reduction.
Service Packages: Tiered plans include scheduled maintenance inspections guaranteed spare parts delivery (24/48/72 hr response) onsite technical support during major overhauls.
Financing Options: Equipment leasing capital loans through partner financial institutions payperton processing agreements available for qualified operations.

8.FAQ

Q1:What exactly is certified as RoHS compliant in the plant?
A1:Certification covers all components that contact the ore or could contaminate it through degradation including crusher liners screen cloths conveyor belt scrapers chute liners used lubricants seals electrical wiring insulation

Q2 Can we retrofit our existing crushing circuit to be RoHS compliant?
A2 Yes retrofits are common The process involves auditing current equipment replacing all critical wear parts with certified versions verifying lubricants greases Typically primary focus is on final crushing stages that have greatest influence on final product

Q3 How does using compliant materials affect wear life compared to standard manganese steel?
A3 Industry testing demonstrates properly formulated compliant alloys match or exceed the wear life performance of standard grades The operational benefit comes from guaranteed purity not a compromise on durability

Q4 What proof of compliance will we receive?
A4 You will receive a comprehensive documentation package including Material Declarations Certificates of Conformity mill test certificates from alloy suppliers full traceability for each major wear component

Q5 How does this impact our overall operating cost OPEX?
A5 While CAPEX may see moderate increase OPEX is positively impacted through reduced compliance risk potential premium product pricing energy savings from optimized design lower maintenance costs due improved reliability systems

Q6 What happens if a component fails unexpectedly? Are compliant spares readily available?
A6 Critical spare parts like liners mantles are held in regional stock under service agreements ensuring availability equivalent standard parts Lead times custom components follow standard manufacturing schedules

Q7 Who verifies the ongoing compliance after installation during operation?
A7 Compliance maintained through use approved spare parts consumables Your operation maintains chain custody documentation provided Periodic audits can be conducted using portable XRF analyzers verify material composition installed parts