Fda Approved Iron Ore Crushing Plant Catalog
1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT
Ограничены ли ваши операции по переработке железной руды из-за непостоянного размера сырья?, внеплановое техническое обслуживание, and rising energy costs? Inefficient primary crushing creates bottlenecks that ripple through your entire beneficiation circuit, directly impacting throughput and profitability. Рассмотрим эти общие проблемы:
Чрезмерное время простоя: Unplanned stoppages for liner changes or mechanical repairs in your primary crusher can cost thousands per hour in lost production.
Высокие эксплуатационные расходы: Inefficient crushing cycles and excessive power draw from poorly matched equipment inflate your costperton metric.
Вариативность качества продукции: Inconsistent output size distribution from the primary stage overloads downstream screening and secondary crushing, снижение общей эффективности установки.
Затраты на абразивный износ: The highly abrasive nature of iron ore leads to rapid wear on crusher components, resulting in high spare parts consumption and labor for replacements.
Is your current primary crushing solution delivering the reliability and costefficiency required in today's market? The foundation of a profitable iron ore plant is a robust, highcapacity primary crushing circuit.
2. ОБЗОР ПРОДУКТА: FDA Approved Iron Ore Crushing Plant
This product description details our engineered primary crushing station, specifically configured for hightonnage iron ore processing. Этот модуль «под ключ» предназначен для первоначального уменьшения объемов горнодобывающих предприятий. (ПЗУ) железная руда, typically reducing material from up to 1.5meter feed down to a conveyable product for further processing.
Операционный рабочий процесс:
1. ROM iron ore is dumped into a heavyduty vibrating grizzly feeder (ВГФФ ВГФ).
2. The VGF removes sub100mm fines via a scalping section and evenly feeds oversize material into the jaw crusher or gyratory crusher.
3. The primary crusher performs the initial compressive breakage of the ore.
4. Crushed product is discharged onto a main plant conveyor for transport to the next processing stage.
Область применения & Ограничения:
Объем: Ideal for greenfield installations or expansion projects requiring capacities from 1,500 слишком 10,000 тонн в час (т/ч). Suited for magnetite, гематит, и другие железосодержащие руды.
Ограничения: Это решение для первичного дробления.; secondary and tertiary crushing require additional circuit design. Feed size must be controlled within the crusher's designed maximum intake dimensions.
3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ
Вибрационный колосниковый питатель HeavyDuty (ВГФФ ВГФ) | Техническая основа: Высокопрочная стальная конструкция с регулируемыми решетками. | Операционная выгода: Scalps fines to bypass the crusher, уменьшает износ, and ensures even feed distribution for optimal cavity utilization | Воздействие на рентабельность инвестиций: Increases effective crusher capacity by up to 15% and extends wear life of primary liners
Гидростатическая система привода дробилки | Техническая основа: Direct hydraulic drive for the main shaft | Операционная выгода: Обеспечивает плавный запуск под нагрузкой, обратимая операция для устранения засоров, и плавное регулирование скорости для оптимальной производительности. | Воздействие на рентабельность инвестиций: Eliminates costly shearing of mechanical drive components; данные поля показывают 30% сокращение времени простоя, связанного с засорением
Модульная конструкция вкладыша | Техническая основа: Segmented manganese steel liners secured with boltin systems | Операционная выгода: Enables partial liner replacement and significantly reduces changeout time compared to monolithic liners | Воздействие на рентабельность инвестиций: Reduces liner maintenance downtime by approximately 40%, снижение затрат на рабочую силу и повышение доступности
Расширенная геометрия камеры | Техническая основа: Computermodeled nip angle and crushing chamber profile | Операционная выгода: Optimizes compressive force application for iron ore’s fracture characteristics, improving reduction ratio and particle shape | Воздействие на рентабельность инвестиций: Delivers a more consistent product size, reducing recirculation load and energy consumption in downstream stages
Централизованная автоматизированная смазка | Техническая основа: Programmable system delivering precise grease volumes to all critical bearings | Операционная выгода: Ensures optimal bearing health regardless of operator intervention, protecting against contaminant ingress in dusty environments | Воздействие на рентабельность инвестиций: Отраслевые испытания демонстрируют прямую корреляцию с 60% increase in major bearing service life
RockBreaker Integration Platform | Техническая основа: Reinforced chassis with preengineered mounting points | Операционная выгода: Allows for safe installation of stationary rock breaker to address hangups at the crusher inlet without manual intervention | Воздействие на рентабельность инвестиций: Mitigates a major safety risk and prevents prolonged stoppages due to bridging
4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА
| Метрика производительности | Отраслевой стандарт (Average Jaw/Gyratory) | Наше решение для дробильных установок для железной руды | Преимущество (% Улучшение) |
| : | : | : | : |
| Доступность (Запланированное время выполнения) | 9294% | 96%+| +34% |
| Время смены вкладыша (Часы) | 2436 часы (full set) | 1418 часы| ~45% быстрее |
| Тоннаж на кВтч (Энергоэффективность) Базовый уровень = 100 Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard = Baseline = Indexed Score = Industry Standard=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=100Index=Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score = Industry Standard)| Indexed Score=|IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard|=IndustryStandard)=105110| +510% |
| Среднее время между отказами (среднее время безотказной работы) Основные компоненты| ~4000 часов| 5,500+ часы| +37% |
5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ
Диапазон мощности: Настраивается из 1,500 tph to 10,000+ т/ч.
Варианты типа дробилки: Heavyduty jaw crusher or primary gyratory crusher.
Максимальный размер подачи: Up to 1,500mm (59").
Диапазон настройки разряда: 150мм 300 мм (6" 12"), adjustable based on model.
Требования к питанию: Суммарная установленная мощность варьируется от 450 кВт до более 1.2 MW depending on capacity selection; предназначен для питания высокого напряжения (6.6кВ типичное).
Характеристики материала: Main frame fabricated from hightensile steel; wear liners manufactured from ASTM A128 manganese steel; вал из кованой легированной стали.
Физические размеры (Module): Approximate footprint range: Length 2540m x Width 812m x Height 810m.
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 30°С до +50°С.; dustsealed bearings and components standard.
6. СЦЕНАРИИ ПРИМЕНЕНИЯ
Проект по производству магнетитовой фабрики Greenfield
Challenge A new mine required a primary crushing plant capable of processing very hard magnetite ore at >6，000 tph with extreme reliability， as any downtime would delay concentrator rampup． Initial designs using standard crushers projected high liner wear costs．
Solution Implementation of our gyratorybased FDA approved iron ore crushing plant with modular liners， hydrostatic drive，and an oversized heavyduty VGF．
Результаты. Достигнута устойчивая производительность 6，200 т/ч during commissioning． Liner life exceeded projections by 18%，and plant availability averaged 96．5％in the first year．
Existing Hematite Processing Plant Expansion
Challenge An aging jaw crusher station was the bottleneck， limiting plant expansion goals． Frequent blockages caused erratic feed to downstream processes，and maintenance was laborintensive．
Solution Replacement with our turnkey FDA approved iron ore crushing plant module，designed as a direct retrofit into the existing flow sheet，including an integrated rockbreaker．
Results Primary throughput increased by 35％immediately． Blockages were reduced by over 90％，and automated lubrication cut scheduled maintenance hours by 25％per month．
7． КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ
Equipment pricing is tiered based on capacity（tph）and selected core crusher type（jaw vs．gyratory）．
Ценовые уровни：
Tier I（7，000 tph）：Configured with large gyratory crushers．
Дополнительные функции：
Усовершенствованные датчики мониторинга состояния (вибрация)，температура）
Интеграция системы пылеподавления
Wear liner monitoring system
Extended warranty packages
Пакеты услуг：
A comprehensive selection is available including：
Ежегодная проверка &optimization plans
Onsite parts inventory holding agreements
Remote diagnostics &technical support packages
Варианты финансирования：
Flexible commercial leasing structures are available through partners，
allowing CAPEX preservation． Project financing may be considered
for largescale developments．
8． FAQ
Q What if my ROM feed size varies significantly？
A The heavyduty VGF和hydrostatic drive are specifically designed to handle variance．The reversible hydraulic drive can clear minor blockages automatically，
and chamber geometry accommodates reasonable fluctuation without significant efficiency loss．
Q How does this solution integrate with my existing control system？
A The FDA approved iron ore crushing plant module comes with its own PLCbased control panel which communicates via standard industrial protocols（Modbus TCP/IP，
Profibus）．It can operate as a standalone unit or be fully integrated into your central SCADA system．
Q What is the expected operational impact on my workforce？
A The design prioritizes safety和reduces manual labor．Features like centralized lubrication，
modular liners和remote diagnostics reduce time spent on hazardous tasks和routine checks，
allowing your team to focus on oversight和optimization．
Q Are there long lead times for critical wear parts？
A We maintain regional inventory hubs for fastmoving wear items like liner sets．
Using proprietary alloy specifications ensures consistent performance和availability．
Q Can you provide assistance with foundation design和civil works？
A Yes．With purchase we provide detailed foundation drawings，
load data和anchor bolt specifications required by your civil engineering contractor
for proper installation．
Q What are the commercial terms典型for such equipment？
A Terms are typically FCA our manufacturing facility．
Перевозки、insurance和installation are quoted separately based on project location．
Payment milestones are tied to engineering approval、manufacturing completion、
and shipment．
Q Is operator training included？
A Comprehensive training on operation、текущее обслуживание、
and safety procedures is included with installation commissioning，
conducted both at our facility during FAT和onsite during startup