1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Управляете ли вы коммерческой совокупной операцией, где последовательно, Большой объем производства имеет решающее значение для прибыльности? Твой 250300 tph stone crushing plant faces significant operational pressures. Inconsistent feed material causes unexpected wear and crusher stalls, leading to costly, незапланированный простой. Energy consumption per ton remains stubbornly high, размывание границ. Meeting strict, dualgrade specifications for base and chip products often requires inefficient, multistage recrushing. Более того, the total cost of ownership—from liner replacements to conveyor maintenance—accumulates faster than projected.

How do you increase plant availability beyond 92%? Can you reduce your cost per ton while maintaining precise product shaping? Is your current setup flexible enough to handle varying rock hardness without sacrificing throughput? Решение требует системы, спроектированной не только с учетом производительности, но для предсказуемого, efficient commercial production.

2. ОБЗОР ПРОДУКТА

Этот 250300tph Turnkey Stone Crushing and Screening Plant is a stationary, hardrock processing solution designed for highvolume production of aggregates (05мм, 510мм, 1020мм, 2031.5мм) and other specification materials. Он объединяет первичное дробление, вторичное/третичное дробление, скрининг, and material handling into a coordinated system.

Операционный рабочий процесс:
1. Первичное сокращение: Dump trucks feed <750mm rock into a vibrating grizzly feeder which bypasses sub100mm fines and directs oversize to a robust primary jaw crusher.
2. вторичный & Третичное дробление: Primary crushed material is conveyed to a cone crusher for intermediate reduction. A second cone crusher or impact crusher in closed circuit performs final shaping and size refinement.
3. Размеры & Классификация: Material is routed to a multideck vibrating screen where it is precisely separated into finished product stockpiles.
4. Рециркуляция: Oversize from the screens is automatically returned via closedcircuit conveyors to the appropriate crusher for further processing.
5. Пылеподавление: Интегрированные системы распыления на перевалочных пунктах контролируют выбросы твердых частиц..

Область применения: Идеально подходит для гранита, базальт, river pebble, известняк, and other abrasive materials with compressive strength up to 350 МПа. Suitable for large quarry operations, поддержка крупных инфраструктурных проектов (шоссе, железные дороги), and dedicated commercial aggregate supply yards.

Ограничения: Not designed for mobile or semimobile applications requiring frequent relocation. Site requires stable foundation preparation and adequate space for plant layout and stockpiling.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Интеллектуальная система управления подачей | Техническая основа: Частотно-регулируемый привод (ЧРП) on feeder & level sensors | Операционная выгода: Maintains optimal chokefeed condition for cone crushers automatically | Воздействие на рентабельность инвестиций: Увеличивает пропускную способность на 812% and reduces liner wear by up to 15%
HeavyDuty Crusher Configuration | Техническая основа: Гидравлическая регулировка & clearing on all crushers | Операционная выгода: Enables rapid CSS changes for product sizing and safe clearing of tramp metal/stalling | Воздействие на рентабельность инвестиций: Reduces downtime for chamber clearing from hours to minutes
Централизованное управление процессами | Техническая основа: PLCbased automation with touchscreen HMI | Операционная выгода: Allows singleoperator monitoring of entire flow from a control room; logs production data | Воздействие на рентабельность инвестиций: Lowers labor costs and provides data for production optimization
Modular Electrical & Hydraulic Design | Техническая основа: Preassembled skids with quickdisconnect couplings | Операционная выгода: Упрощает установку, ввод в эксплуатацию, and future maintenance access | Воздействие на рентабельность инвестиций: Reduces installation time by ~30% and lowers service costs
MultiStage Dust Suppression | Техническая основа: Pressurized spray nozzles at key transfer points with moisture sensors | Операционная выгода: Effectively controls dust without overwetting material | Воздействие на рентабельность инвестиций: Ensures environmental compliance and protects downstream equipment

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт (250300т/ч Завод) | Это решение для завода производительностью 250–300 тонн в час | Преимущество (% Улучшение) |
| : | : | : | : |
| Доступность завода | 88 91% | 92 95%| +4% (Сокращение времени простоя) |
| Потребляемая мощность (кВтч/тонна)| 1.8 2.2 кВтч/т | 1.65 1.85 кВтч/т| До 12% (Экономия энергии) |
| Жизнь лайнера дробилки (Абразивный камень)| ~450 часов работы| 520+ часы работы| +15% (Reduced Wear Cost) |
| Индекс формы продукта (Лязгкость)| >18% in chip products| <15% in chip products| Более высокая ценность продукта |
| Время реконфигурации (Изменение CSS)| Ручная регулировка шайбы (~4 hrs)| Гидравлическая регулировка (~30 min)| 87% (Операционная гибкость) |

5.ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Расчетная пропускная способность: 250 300 метрические тонны в час (из расчета плотности материала ~1,6 т/м³)
Первичная дробилка: Jaw Crusher Model JC1303 / Кормовое отверстие:1300х300 мм / Максимальный размер подачи: ≤750 мм
Вторичные/третичные дробилки: Two units of Cone Crushers Model CC300 / Each with hydraulic adjustment & очистка
Группа скрининга: Tripledeck Vibrating Screen Model VS2460 / Область экрана: ~14 sqm
Требование к питанию: Общая установленная мощность приблизительно 650 кВт; Mains connection recommended at400V/50Hz or480V/60Hz.
Основные характеристики материалов: Main frame construction Q345B steel; Conveyor belts EP630/4; Crusher liners Mn18Cr2 high manganese steel.
Физические размеры (Прибл.): Overall layout length ~85m; width ~25m; max height ~12m.
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 20°С до +45°С.; dust emission concentration at outlet ≤20mg/m³.

6\. СЦЕНАРИИ ПРИМЕНЕНИЯ

Производство базового слоя шоссе | Испытание:A national contractor required consistent,sustained production of Class A base course(031\.5мм)and chip sealing aggregates(510мм)from hard granite for a toll highway project.Plant stoppages directly threatened project timelines.| Решение:A turnkey250\300tph plant was installed featuring twostage cone crushing in closed circuit with precise screening.The automated control system allowed quick switching between product specifications.| Результаты:The plant achieved an average output of280tph over22months.Availability averaged94\.2%.The consistent cubical shape of the chip product reduced bitumen consumption by an estimated7%,noted by the paving contractor.

Commercial Quarry Expansion Challenge:A regional quarry operator needed to upgrade from150tph to meet new supply contracts but had limited space for expansion and needed to maintain production during phased commissioning.| Решение:The modular design of the250\300tph plant allowed it to be constructed parallel to the old line.Critical preassembled skids reduced onsite assembly time.The old line was decommissioned only after the new plant was fully operational.| Результаты:The expansion was completed with only48hours of total production stoppage.The new plant's energy efficiency reduced power costs by$0\.11per ton produced,increasing annual gross margin significantly.

Limestone Processing for Concrete Aggregates Challenge:A readymix concrete supplier's own aggregate plant struggled with excessive fines generation(<0\.075мм)and poor shape in the critical10\20mm fraction,increasing cement demand in their mixes.| Решение:The plant configuration prioritized lowwear,cubicalproduct crushing stages.An impact crusher was selected as the tertiary unit,and screen deck configurations were optimized to remove excess fines early.| Результаты:Fines generation was reduced by22%.The improved particle shape increased the workability of the concrete mix.Field data showed a potential3\5%reduction in cement usage while maintaining slump specifications.

КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Pricing is structured around core configuration levels:

• Уровень 1(Базовая конфигурация):Включает первичную щековую дробилку,одноконусная дробилка,tripledeck screen,основные конвейеры,and central control panel.Priced as acapital investmentfor standard materials like limestone.
• Уровень 2(Расширенная конфигурация):Adds secondary cone crusherfor full closedcircuit operation,intelligent VFD feed control,and enhanced dust suppression.Recommendedfor abrasive materials(гранит,базальт).
• Уровень 3(Пользовательская конфигурация):Incorporates specific options such as washing systemsfor manufactured sand,finer screening decksfor specialized products,and extended weather protection enclosures.

Дополнительные функции включают телематику удаленного мониторинга.,mobile generator hookups,and automated lubrication systems.Service packages range from basic commissioningand operator trainingto comprehensive annual maintenance contracts with guaranteed parts availability.Financing options including equipment leasingand term loans are available through partnered financial institutions,making capital expenditure manageable against longterm supply contracts.

Часто задаваемые вопросы

вопрос:What if my feed material size or hardness varies frequently?
А:The hydraulic adjustment on the crushers allows operators to change the Closed Side Setting(CSS)in minutes via the control panel.This adapts the crushing chamberto different conditions without stopping production,a key featureof this commercial stone crushing plantsolution.

Q.How many operators are requiredto run this plant?
A.The centralized PLC automationis designedfor singlestation control.One trained operatorin the control room can manage the entirecrushingandscreening process.Routine ground inspectionsare still recommended,but direct machinelevel operationis not required.

Q.Can this system integratewith our existing primary feedingor downstream equipment?
A.YES.The design includes standardized feedand discharge heights.Conveyor lengthsand transfer pointscan be modifiedduring engineering.We will review your site layoutto ensure compatibilitywith your current stockpile feedersor existing tertiary processing lines.

Q.What isthe typical installationand commissioning timeline?
A.For aprepared foundation site,the modular skidded components allow erectionin approximately8\10weeks.Commissioningand performance testingtypically takes an additional1\2weeks.This timeframe assumes all civil worksare complete prior todelivery.

Вопрос: Доступны ли запасные части?,and what arethe lead times?
A.We maintaina strategic inventoryof highwear parts(челюстные пластины,мантии,сетки экрана).For standard wear parts,the commitmentis shipmentwithin72hours.For major components,a stocklistwith guaranteed lead timesis providedwith themaintenance contract.

Q.What kindof trainingis providedfor our maintenance team?
A.Comprehensive trainingincludes both classroom instructionon system principlesand handson field training.It covers daily checks,troubleshooting usingthe HMI diagnostics,регламентные процедуры технического обслуживания,and safe liner changeout protocols.Training documentationis supplied digitallyandin print