1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Снижается ли рентабельность переработки железной руды из-за постоянного, незапланированный простой? Commercial operators and plant managers face significant financial pressure from equipment that cannot withstand the abrasive reality of highvolume iron ore. Общие проблемы включают в себя:
Чрезмерный износ & Отказ компонента: Standard crushing chambers and liners degrade rapidly under continuous Taconite or Hematite load, leading to frequent shutdowns for maintenance and high parts replacement costs.
Непостоянная пропускная способность & Градация продукта: Fluctuations in feed size or hardness result in poor control over final product sizing, causing bottlenecks in downstream grinding circuits and reducing pellet or sinter plant efficiency.
Высокое энергопотребление на тонну: Older or improperly configured crushing stages consume disproportionate power, directly impacting operational expenditure and carbon footprint.
Жесткая конфигурация установки: Fixed crushing circuits struggle to adapt to varying ore body characteristics or market demands for different product specifications, ограничение операционной гибкости.

Is your primary crushing station a source of cost or a driver of profit? The solution lies in precision engineering applied directly to the unique demands of iron ore.

2. ОБЗОР ПРОДУКТА

This content details a fully customizable, heavyduty stationary crushing plant solution engineered explicitly for hightonnage iron ore processing. The system is designed as a primary or primary/secondary stage unit, built around a core gyratory or jaw crusher configured for maximum abrasion resistance and volumetric throughput.

Операционный рабочий процесс:
1. Managed Feed Intake: Runofmine ore is directed via heavyduty apron feeder to the primary crusher, ensuring a consistent, chokefed load for optimal crushing action.
2. Первичное уменьшение размера: The core crusher utilizes high inertia and optimized kinematics to reduce large lump ore (до 1,5 м) to a manageable conveyorable size.
3. Первичный скальпинг & Удаление штрафов: A downstream heavyduty scalper removes natural fines prior to secondary crushing, increasing circuit efficiency and reducing unnecessary wear.
4. Вторичное дробление & Closed Circuit Control (Необязательный): A cone crusher module in closed circuit with a sizing screen allows precise control of final product gradation, typically to 50mm or 75mm for downstream milling.
5. Комплексная обработка материалов: Plant design includes robust conveyor systems, transfer points with impact beds, and dust suppression integration for complete material flow management.

Область применения: Designed for greenfield installations or major upgrades in magnetite (таконит) and hematite mining operations with annual capacity requirements from 5 к 25+ миллион тонн.

Ограничения: Не подходит для малотоннажных операций. (< 1 Mtpa) or as a tertiary/quartzite crushing unit without significant specification review.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Запатентованная геометрия вкладыша | Техническая основа: Конечно-элементный анализ (ВЭД) & носить моделирование | Операционная выгода: Обеспечивает более последовательную градацию продукта на протяжении всего жизненного цикла футеровки., with reduced risk of bridging | Воздействие на рентабельность инвестиций: До 15% longer liner life reduces direct parts cost and changeout downtime

Интеллектуальная нагрузка & Система управления подачей | Техническая основа: Realtime motor power & hydraulic pressure monitoring with automated feeder response | Операционная выгода: Maintains optimal crusher cavity loading, preventing overload stalls and emptycavity wear | Воздействие на рентабельность инвестиций: Защищает компоненты привода от ударных нагрузок; данные поля показывают 712% снижение удельного энергопотребления (кВтч/тонна)

Modular Plant Subframe Design | Техническая основа: Скрепляем вместе, heavygauge steel modules with precisionmachined interfaces | Операционная выгода: Enables faster onsite erection and future reconfiguration or relocation with minimal cutting/welding | Воздействие на рентабельность инвестиций: Can reduce civil works and installation time by an estimated 30%, ускорение времени производства

Централизованная смазка & Fluid Systems | Техническая основа: Singlepoint lubrication distribution blocks with monitoring points for all critical bearings | Операционная выгода: Ensures correct lubrication intervals are met reliably, extending bearing service life in highdust environments | Воздействие на рентабельность инвестиций: Lowers manual maintenance labor hours by ~25% per shift and decreases bearing failure risk

HeavyDuty Dust Containment Skirting | Техническая основа: Multistage rubber skirting with adjustable tensioning on all conveyor transfers | Операционная выгода: Dramatically reduces airborne dust at emission points, повышение безопасности объекта и соблюдения экологических требований | Воздействие на рентабельность инвестиций: Lowers water consumption for suppression and reduces cleanup costs; minimizes risk of regulatory noncompliance penalties

Crusher Backing Material Integration | Техническая основа: Automated dispensing system for epoxy resin backing during liner installation | Операционная выгода: Ensures complete cavity fill without air pockets, maximizing liner stability and energy transfer | Воздействие на рентабельность инвестиций: Eliminates premature liner failure due to improper backing, protecting major crusher body components

Платформы для обслуживания WalkIn | Техническая основа: Integrated, OSHAcompliant platforms with handrails around all major service points (crusher top shell, мотор, снопы) | Operational Benefit Provides safe, direct access for inspection and component handling during planned maintenance| ROI Impact Reduces servicerelated safety incidents; improves maintenance efficiency by providing stable work areas

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт (Средний) | Индивидуальное решение для дробильной установки для железной руды | Преимущество (% Улучшение) |
| : | : | : | : |
| Лайнер Жизнь (Primary Mantle/Bowl) | ~1.2 Million Tonnes
Зависит от абразивности руды| ~1.5 Million Tonnes
Based on magnetite feed| +25% |
| Total Plant Availability (Запланированное время выполнения) | 9294%
Includes minor stops| >96%
Design target| +34 Процентные пункты |
| Удельное энергопотребление
(кВтч на тонну измельченного) Baseline Dependent
Зависит от конструкции схемы| Field data indicates reduction of
712% против. nonoptimized equivalent systems.| До 12% |
| Среднее время между отказами (среднее время безотказной работы)
for Major Components
~2，000 часы
Drive/motor/bearing assemblies| >2，500 часы
Design target based on load management| +25% |
| Плановый простой при техническом обслуживании
(per major liner change event)
4872 часы
Crew dependent|<36 hours target
Via modular liners & платформы| 33% |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Диапазон мощности: Настраивается из 2，500 слишком 8，000 тонн в час (т/ч)， в зависимости от размера корма， ore work index，and product size requirement.
Варианты первичной дробилки: Вращающиеся дробилки (54Загрузочное отверстие «75») или щековые дробилки (60”x80”+). Selection based on required throughput， feed topology，and fragmentation analysis.
Мощность привода: Электроприводы начиная от 450 кВт до 1，200 кВт，with Vbelt or direct drive configurations available。 Softstart systems standard。
Характеристики материала：
Дробильные вкладыши： Manganese steel alloy（14%18%）with optional chrome carbide overlay for extreme abrasion zones。
Конструкционная сталь： Primary support structures use S355JR grade steel； highwear areas utilize AR400 abrasionresistant plate。
Conveyor Idlers： CEMA class E/F sealed bearings； ударные ролики в зонах погрузки。
Physical Dimensions （Modular）： Modules designed for standard shipping container dimensions。 Typical primary station footprint： ~30m L x 15m W x 20m H （variable）。
Экологический рабочий диапазон：
Температура окружающей среды： 30°C to +50°C （with appropriate lube oil/heater packages）。
Выбросы пыли： Designed to achieve <10 mg/Nm³ at containment points with integrated suppression。
Уровень шума： Compliant with <85 дБ(А) at operator stations via acoustic enclosures。

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Greenfield Magnetite Concentrator｜Challenge： A new mine required a primary crushing plant capable of processing highly abrasive taconite at 6，000 т/ч，with strict product sizing (250мм) for SAG mill feed。 The remote location demanded high reliability due to limited local maintenance support。｜Решение： A customized gyratory crusherbased plant featuring our intelligent load control system， extendedlife liner package，and fully walkin maintenance modules was installed。 All lubrication and electrical cabinets were housed in heated enclosures。｜Результаты： Завод вышел на проектную мощность через две недели после ввода в эксплуатацию.。 Срок службы лайнера превысил прогноз на 8%， achieving over 1。6 million tonnes per set。 Availability has averaged 96。7% over the first three years of operation。

Hematite Processing Plant Upgrade｜Challenge An existing hematite operation experienced chronic bottlenecks due to an aging jaw crusher plant suffering from frequent bearing failures and poor throughput consistency (<2，200 т/ч)，limiting downstream beneficiation output。｜Solution We replaced the existing unit with a customized modular jaw plant featuring the centralized greasing system，heavyduty skirting，and an optimized feeder/crusher interface geometry tailored to the specific ore characteristics。｜Results Throughput increased consistently above design rate of 2，800 т/ч。 Bearingrelated unscheduled downtime was eliminated in the first year postinstallation。 Product size distribution became markedly more uniform (+/10%) improving downstream screening efficiency。

7． КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Our approach is based on providing transparent value aligned with your production targets。

Ценовые уровни
• Base Plant Configuration Includes core crusher motor feeders basic discharge conveyor structural supports walkways ladders
• Enhanced Configuration Adds intelligent control system dust suppression package premium liner options automated lubrication
• Turnkey Project Package Full engineering procurement construction management EPC/M including foundations electrical reticulation commissioning spares package

Дополнительные функции
• OnBoard Hydraulic Power Unit For setting adjustment/clearing
• Rock Breaker Boom System For oversize breaking at grizzly
• Advanced Predictive Monitoring Vibration temperature sensors linked to SCADA
• Modular Secondary/Tertiary Crushing Stage For future expansion

Пакеты услуг
• Planned Maintenance Agreements Scheduled inspections parts supply labor rates defined upfront
• Performance Guarantee Contracts Uptime availability或throughput guarantees supported by remote monitoring
• Liner Service Programs Fixedcostpertonne agreements covering all wear parts

Варианты финансирования
We work with accredited partners to offer equipment leasing capital loans以及operational expenditure OpEx models where payment is tied directlyto verified production tonnage。

8． FAQ

Q What level of site preparation is required prior delivery？
A Our modular plants require prepared concrete foundations designed specificallyfor your soil conditions We provide full foundation drawings anchor bolt locations as partof basic engineering Minimal field welding should be required。

Q How does this solution integrate into my existing control room SCADA system？
A The plant control panel can be supplied asa standalone PLCbased systemor configuredto communicate via industrystandard protocols Modbus TCP/IP Profibus etc allowing full visibilityand control fromyour central facility。

Q Are performance guarantees offered？
A Yes subjectto mutually agreedupon feed material specifications we can contractually guarantee rated throughput capacity final product P80 sizing以及specific energy consumption targets。

Q What isthe typical lead timefrom order placementto commissioning？
A For standard configurations lead times range between914 months dependingon current manufacturingload Complex customizations may extendthis timeframe Detailed project schedules are provided upon initial technical review。

Q How do you address ongoing technical supportfor remote sites？
A We offer tiered support including24/7 remote diagnostics access trained regional service technicians以及comprehensive documentation Parts are strategically warehousedin key mining regions globallyto expedite delivery。

Q Can this plant be relocatedin future？
A Yes themodular bolted subframe designis specifically engineeredfor disassembly relocation andreassembly Minimally destructive techniquesare used preserving structural integrity Relocation feasibility studiesare availableas separate consultancy service。

Q What trainingis providedfor our operationsand maintenance teams？
A Comprehensive trainingis included covering normal operation shutdown procedures routine maintenance tasks troubleshooting We provide both classroom sessionsat our facility handson training during commissioningat yours alongwith detailed operational manuals