Crushing And Screening Equipment Producers Cheap
1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT
Растущие эксплуатационные расходы и непредсказуемые простои снижают рентабельность вашего проекта? Для руководителей заводов и инженерных подрядчиков, контур дробления и сортировки часто является источником критических узких мест. Общие проблемы включают в себя:
Высокие затраты на техническое обслуживание: Частые поломки подшипников., меняется ткань экрана, and conveyor belt wear from improper material flow can consume 1520% of your annual operating budget.
Внеплановые простои: A primary crusher failure or screen box structural issue can halt an entire site, costing tens of thousands per hour in lost production and labor.
Неэффективный материальный поток: Poorly matched equipment leading to recirculating loads, chokefeeding, or underutilization reduces overall system capacity by up to 30%.
Непоследовательная градация продукта: Offspec aggregate or mineral product results in costly recrushing, stockpile segregation issues, and rejected loads.
Рост энергопотребления: Старше, mechanically inefficient drives and components directly increase your kWhperton cost, a key metric under constant pressure.
Is your operation equipped to minimize these risks while maximizing throughput and product quality? The foundation lies in selecting robust, intelligently engineered crushing and screening equipment.
2. ОБЗОР ПРОДУКТА
This content outlines the critical considerations for stationary and trackmounted crushing and screening equipment, the core machinery for reducing raw feed material (например, quarry rock, переработанный бетон, mineral ore) в указанные совокупные размеры. Операционный документооборот представляет собой непрерывный процесс:
1. Первичное уменьшение размера: Large feed material is reduced by jaw or gyratory crushers.
2. Material Transport & Скальпинг: Conveyors move material to vibrating screens that remove undersize material prior to secondary crushing.
3. Вторичное/Третичное дробление: Cone or impact crushers further reduce material to required dimensions.
4. Финальный показ & Сортировка: Multideck screens accurately separate crushed material into precise product fractions (например, ¾” chip, искусственный песок).
5. Накопление запасов & ReCirculation: Onspec product is conveyed to stockpiles; oversize material is recirculated back into the circuit.
Область применения включает добычу полезных ископаемых, добыча полезных ископаемых, строительство & снос, переработка, и совокупное производство. Key limitations involve feed material abrasiveness (impacting wear life) и требуемые характеристики конечного продукта (dictating circuit design).
3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ
Запатентованная геометрия камеры | Техническая основа: Computermodeled kinematics and cavity profiles | Операционная выгода: Optimized nip angle and crushing stroke for higher reduction ratios with less wear on manganese surfaces | Воздействие на рентабельность инвестиций: До 12% lower costperton in abrasive applications due to extended liner life.
Modular Screen Media System | Техническая основа: Quicktensioning wedgelock design with polyurethane damping | Операционная выгода: Screen deck changes completed in under 2 hours versus a typical 68 hour shift, with consistent tension for longer cloth life | Воздействие на рентабельность инвестиций: Reduces labor hours for maintenance by ~70% per changeout, повышение эксплуатационной готовности завода.
Централизованная смазка & Мониторинг состояния | Техническая основа: Automated lube points with flow sensors feeding a central PLC | Операционная выгода: Ensures critical crusher and screen bearings receive precise lubrication without manual intervention; alerts operators to blockages | Воздействие на рентабельность инвестиций: Prevents an estimated 85% of bearingrelated failures, avoiding associated downtime costs.
Hybrid Power Drive System | Техническая основа: Dieselelectric configuration with onboard genset or external grid connection capability | Операционная выгода: Operators can select the most costeffective power source; electric mode reduces fuel consumption by 100% when grid power is available | Воздействие на рентабельность инвестиций: Field data shows average energy cost savings of 2540% in hybrid mode versus dieselonly operation.
HeavyDuty Feeder with PreScreening Section | Техническая основа: Grizzly feeder with integrated stepped grizzly bars or punch plate section | Операционная выгода: Removes natural fines and subproduct size material before the primary crusher, reducing chamber volume usage and wear | Воздействие на рентабельность инвестиций: Increases effective primary crusher throughput by up to 15% by eliminating precrushed material.
Reinforced Structural Frame Design | Техническая основа: Конечно-элементный анализ (ВЭД) optimized steel fabrication with highstress zone reinforcements | Операционная выгода: Withstands continuous highcycle loading without frame fatigue or cracking common in highproduction environments | Воздействие на рентабельность инвестиций: Eliminates unplanned structural repairs, protecting asset lifespan over a 15+ year service period.
4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА
| Метрика производительности | Стандартный эталон отрасли | Наше сокрушение & Screening Solution Documented Performance | Преимущество (% Улучшение) |
| : | : | : | : |
| Crusher Liner Wear Life (Абразивный камень) | ~450,000 tons per set (Cone Crusher Mn18) | ~520,000 tons per set (Proprietary Mn22 Alloy) | +15% Долгая жизнь |
| Screen Box Sideplate Vibration Fatigue Failure Mean Time Between Failure (среднее время безотказной работы) | ~8,000 operating hours before weld repair required| >14,000 operating hours before inspection advised| +75% Improved Durability |
| Энергопотребление (kWh per Ton Processed) Baseline for a 300tph Circuit| ~0.85 kWh/Ton Average| ~0.72 kWh/Ton Documented Average| 15% Более низкая стоимость энергии |
| Общая стоимость владения (ТШО) над 5 Years (Обслуживание + Части + Время простоя)| Indexed at 100% для сравнения| Оценка в 7882% of benchmark TCO| 18% к 22% Lower TCO |
5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ
Диапазон мощности: Стационарные установки из 150 слишком 1,200 тонн в час (ТПХ). Trackmounted mobile units from 200 к 500 ТПХ.
Требования к питанию: Primary crushing units typically require 150400 kW drives. Full electric stationary plants may require a total connected load of 8002,500 кВА в зависимости от масштаба.
Характеристики материала: Fabricated from S355JR structural steel; highwear components utilize HB500 abrasionresistant steel liners; crusher jaws/cones in premium manganese steel (Мн18Кр2/Мн22Кр2).
Физические размеры (Example Mobile Unit): Transport length approx.16m; Operating length approx.19m; Max height approx.4m; Operating weight approx.45 tonnes.
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 25°С до +45°С.; пылезащищенные подшипники (IP65+); capable of operating at altitudes up to 3,000 meters with engine deration.
6. СЦЕНАРИИ ПРИМЕНЕНИЯ
Проект расширения гранитного карьера
Challenge A major quarry needed to increase production by 40% without expanding their permitted footprint or adding a second processing shift.
Solution Implementation of a new tertiary crushing stage featuring a highspeed cone crusher paired with a tripledeck fine screen in closed circuit.
Results Achieved target throughput increase within existing footprint. The closedcircuit design reduced recirculating load by over half compared to the old layout while improving cubicity of the chip products.
Урбан С&D Recycling Operation
Challenge Processing highly variable construction demolition waste led to frequent jamming in the primary impact crusher from uncrushable rebar matts and excessive fines clogging screens.
Solution Deployment of a heavyduty jaw crusher as primary stage for better tramp metal tolerance and an aggressive linear stroke screen ahead of secondary processing for fines removal.
Results Unplanned stoppages due to feeding issues decreased by approximately90%. The removal of fines early in the circuit significantly improved efficiency of downstream sorting equipment.
7 КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ
Equipment pricing tiers are structured around capacity capability:
Уровень I (600 ТПХ): Customengineered stationary crushing and screening plants.
Optional features include advanced dust suppression systems automated metal detection/ ejection magnetic head pulleys extended conveyor systems
Service packages range from basic warranty support through comprehensive multiyear maintenance agreements including scheduled parts kits
Financing options are available including capital lease operating lease commercial loans tailored
8 Часто задаваемые вопросы
What level of ground preparation is required for installing this equipment?
Stationary plants require engineered concrete foundations Mobile track mounted units require stable compacted ground but minimal civil work enabling rapid redeployment
How does your equipment interface with our existing conveyors stackers?
Our engineering team provides detailed interface specifications for chute heights discharge trajectories belt widths ensuring compatibility
Каково типичное время выполнения заказа с момента ввода заказа в эксплуатацию??
For standard mobile units lead time is typically weeks For large custom stationary plants detailed engineering procurement fabrication requires months
Предоставляете ли вы гарантии выполнения?
Yes we offer guaranteed minimum capacity based on agreed feed material specifications Guarantees are backed by pre purchase material testing circuit simulation
What operator training technical support do you provide?
We include comprehensive onsite training for operations maintenance crews along with digital manuals Access remote diagnostic support via data link standard