1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Are escalating operational costs and unpredictable downtime eroding your iron ore processing margins? Plant managers and engineering contractors face persistent challenges in primary crushing stages that directly impact downstream efficiency and profitability. Общие болевые точки включают в себя:
Чрезмерный износ & Затраты на техническое обслуживание: Abrasive iron ore rapidly degrades crusher liners, leading to frequent shutdowns for replacement, high spare parts expenditure, and lost production.
Unplanned Downtime from Tramp Metal: Hidden scrap metal or uncrushable material in feed causes catastrophic damage to crusher internals, resulting in days of unscheduled downtime and sixfigure repair bills.
Inconsistent Feed Size & Capacity Bottlenecks: Poorly sized feed from the mine or an inefficient primary crusher creates choke points, limiting throughput and preventing the plant from reaching its designed capacity.
Высокое энергопотребление на тонну: Older crushing technology often operates at low mechanical efficiency, making energy one of the largest variable costs with poor ROI on power spend.
Выбросы пыли & Соответствие требованиям безопасности: Inadequate containment at primary crushing points creates hazardous work environments, triggers regulatory noncompliance risks, and represents valuable product loss.

Is your current primary crushing solution a reliable asset or a constant source of cost and delay? The right engineered Chinese Iron Ore Crushing Plant addresses these challenges directly.

2. ОБЗОР ПРОДУКТА

This solution is a heavyduty, stationary primary crushing station engineered specifically for the volumetric reduction of runofmine (ПЗУ) железная руда. It is centered on a robust gyratory or jaw crusher designed for maximum reliability and throughput in highabrasion applications.

Операционный рабочий процесс:
1. ROM iron ore is dumped into a reinforced hopper by haul trucks.
2. A vibrating grizzly feeder (ВГФФ ВГФ) removes fine material (100мм) via a bypass chute while evenly feeding oversize material to the primary crusher.
3. The core primary crusher reduces the ore to a nominal product size of 150250mm through compressive force.
4. Crushed material is discharged onto a main conveyor system for transport to secondary crushing or stockpiling.

Область применения: Ideal for greenfield mine development or brownfield plant expansion requiring highcapacity (2,000 10,000+ ТПХ), continuousduty primary reduction of magnetite, гематит, or other ironbearing ores.

Ограничения: Not suitable for portable or semimobile applications without significant structural modification. Requires stable foundational concrete works and planned feed control for optimal performance.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Конструкция дробилки для тяжелых условий эксплуатации | Техническая основа: Highchromium alloy cast iron liners & reinforced mainframe | Операционная выгода: Extended service life in highly abrasive conditions; withstands peak loading from large feed blocks | Воздействие на рентабельность инвестиций: Снижает частоту замены вкладышей на 3050%, lowering parts inventory cost and maintenance labor hours.

Integrated Tramp Iron Protection | Техническая основа: Hydraulic overload relief system with automatic reset | Операционная выгода: Prevents major damage by allowing the crusher to open its setting to pass uncrushable material, then automatically return to original setting | Воздействие на рентабельность инвестиций: Eliminates costly unplanned downtime events and associated component damage, protecting millions in capital equipment.

Intelligent Feed Control System | Техническая основа: Variablefrequency drive (ЧРП) on feeder coupled with crusher amp monitoring | Операционная выгода: Automatically regulates feed rate to maintain optimal cavity level and prevent choking or running empty | Воздействие на рентабельность инвестиций: Maximizes throughput capacity by 515% while reducing specific energy consumption (кВтч/тонна).

Расширенная интеграция пылеподавления | Техническая основа: Sealed transfer points with strategically placed fog cannons using minimal water | Операционная выгода: Contains dust at source, improving site visibility and air quality for operators | Воздействие на рентабельность инвестиций: Ensures regulatory compliance, reduces cleanup costs, and minimizes product loss as airborne fines.

Modular Walkway & Maintenance Design | Техническая основа: Prefabricated access platforms, hydraulicassisted liner change systems | Операционная выгода: Обеспечивает безопасность, efficient access for inspection and routine maintenance tasks | Воздействие на рентабельность инвестиций: Сокращает время плановых простоев при техническом обслуживании до 40% and significantly improves worker safety metrics.

Централизованная смазка & Мониторинг состояния | Техническая основа: Automated lubrication system with PLC control and vibration/temperature sensor ports | Операционная выгода: Ensures critical bearings receive precise lubrication; enables predictive maintenance scheduling | Воздействие на рентабельность инвестиций: Extends bearing life by over 20% and prevents unexpected failures through datadriven insights.

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Базовый уровень отраслевого стандарта | Это решение для дробильной установки для железной руды | Преимущество (% Улучшение) |
| : | : | : | : |
| Лайнер Жизнь (Абразивная руда) | На основе стандартной марганцовистой стали | Proprietary alloy matrix & конструкция камеры| +3550% |
| Оперативная доступность (Planned) | ~92% (including liner changes) |>96% (with fastchange systems)| +4+ процентные пункты |
| Удельное энергопотребление| Varies by design; базовый уровень = 100%| Оптимизированная кинематика & VFD control| Reduction of 812% |
| Tramp Metal Incident Recovery Time| 2472 hours for inspection/repair|90% |
| Стабильность пропускной способности (против. Дизайн)| ±15% fluctuation common|< ±5% fluctuation with smart feed control| Significantly more stable output |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Диапазон мощности: Настраивается из 2,000 слишком 12,000 метрические тонны в час (ТПХ), depending on model selection and ore characteristics.
Primary Crusher Types Available: Heavyduty gyratory crushers (54”75” feed opening) or large jaw crushers.
Требования к питанию: Главные приводные двигатели от 300 кВт до 800 кВт. Total installed plant power varies with ancillary equipment.
Характеристики материала: Mainframe construction from welded steel plate; liners in highchrome alloy iron; wear surfaces lined with replaceable AR400 steel plates.
Физические размеры (Прибл., Gyratorybased plant): Footprint ~25m L x 15m W x 20m H (excluding feed hopper ramp).
Экологический рабочий диапазон: Designed for ambient temperatures from 30°C to +45°C; пыленепроницаемые электрические шкафы; IP65 rating on critical components.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Large OpenPit Magnetite Mine Expansion

Испытание: An existing operation needed to double primary crushing capacity but had limited space for expansion within the pit perimeter. Downtime during tiein was also a critical concern.
Решение: Implementation of a preassembled modular Chinese Iron Ore Crushing Plant on a new bench adjacent to the existing setup. The plant was factorytested before shipment.
Результаты: The modular approach reduced onsite construction time by 60%. The new plant achieved design throughput of 6,500 TPH within one week of commissioning, with zero impact on existing production during installation.

Модернизация завода по переработке гематита

Испытание:Aging primary jaw crushers suffered from excessive vibration, frequent bearing failures,and an inability to handle increasingly hard ore lenses,causing constant bottlenecks.
Solution Replacement with a modern gyratorybased Chinese Iron Ore Crushing Plant featuring advanced base frame designand automated lubrication.The installation included upgraded rock breaker stations at the feed tip
Results Unplanned breakdowns at primary stage were eliminated Throughput increased by22 due to superior reduction ratioand consistent feeding Annual maintenance costs decreased by an estimated35

7.КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Equipment pricing is tiered based on capacityand selected core crusher technology:
Уровень 1(20004000ТПХ):Based on large jawcrusher technology
Уровень 2(40008000ТПХ):Based on midrangegyratorycrushers most commonfor major projects
Tier3(8000ТПХ+):Customengineeredgyratorysystems

Дополнительные функции включают в себя:
On skidmounted lubrication systems
Advanced predictive monitoring packages wireless sensor networks
Extendedwear packagesfor critical chutesand conveyors
Turnkey installation supervisionand commissioning services

Доступные пакеты услуг:
Standard warranty covering partsand laborfor12months
Extended performance agreementscovering total costper toncrushed
Annual inspectionand condition assessmentreports

Financing Options Project financing can be structured through partner institutions including leaseto own arrangementsor milestonebased payment plans alignedwith project development schedules

8.Часто задаваемые вопросы

Q What levelof preparationis requiredat my sitebefore installation?
A A level compacted platformwith engineered concrete foundationsis required Detailed civil drawingsare provided earlyin the project cyclefor site preparationto proceedin parallelwith equipment manufacturing

Q How does thisplant ensure compatibilitywith my existing secondarycrushingandscreening circuit?
A Our engineering teamwill reviewyour downstream equipment specificationsand product size requirementsThe discharge openingand conveyor interfaceof theprimary plantare designedto matchyour existing flow sheetensuringa smooth integration

Q Whatisthe expected timelinefrom orderto commissioning?
A For standard configurationslead timesrange from8to14months dependingon scaleand complexityThis includes manufacturing factory testing disassemblyfor shipping ocean freightand re assembly onsite Timelinesare defined clearlyin the project scheduleupon order confirmation

Q Are spare parts readily availablegiven the geographic locationof manufacture?
A Yes Critical wear parts are stockedin regional warehouseson multiple continents Furthermorea digital inventoryof your plant’s specific partswith detailed drawingsis providedto facilitate local machiningif ever requiredin an emergency

Q Can thisplant be automatedto tieintoa centralcontrol room?
A AbsolutelyThe crushingplantis controlledbyits ownPLCwhichis fullycapableof interfacingwith your broaderplant DCSor SCADA systemusing standard industrial protocols(eg Profibus Ethernet/IP)Remote monitoringand controlare standard features