H1: ODM Stationary Crushing & Сортировочный завод: Разработано для максимального времени безотказной работы и тоннажа

1. Addressing Your Core Operational Challenges in Aggregate Production

Managing a fixed crushing site presents distinct, дорогостоящие проблемы. Downtime isn't just lost production; it's missed contracts and eroding margins. Вы столкнулись:
Незапланированные остановки: Неисправности подшипников, засоры дробилки, and conveyor issues can halt your entire line. Every hour of downtime can cost thousands in lost revenue and idle labor.
Непоследовательный конечный продукт: Fluctuations in feed material or improper calibration lead to offspec aggregate, что приводит к отказу от продукта, повторные затраты, и испорченные отношения с клиентами.
Высокая сложность обслуживания: Disjointed equipment from multiple suppliers creates a spare parts nightmare and extends maintenance windows, straining your operational budget.
Неэффективный материальный поток: Bottlenecks between crushing stages or screening units cap your plant's true capacity, forcing you to run longer hours at higher cost per ton.
Рост операционных затрат: Energyinefficient drives, чрезмерный расход быстроизнашивающихся деталей, and high manual labor for monitoring directly reduce your profitability per cubic meter.

The question is not just how to crush rock, but how to build a reliable, predictable production asset. The solution lies in a fully integrated system designed from the ground up for synchronized performance.

2. Обзор продукта: The Integrated Stationary Crushing & Сортировочный завод

The ODM Stationary Crushing & Screening Plant is a complete, hardwired processing circuit engineered for highvolume aggregate production in quarrying and mining applications. It transforms raw feed (0800мм) into precisely graded final products (например, 05мм песок, 520мм заполнитель).

Операционный рабочий процесс:
1. Первичное кормление & Дробление: Dump trucks feed a vibrating grizzly feeder which removes fines and directs oversize to a robust primary jaw crusher for initial size reduction.
2. Промежуточная обработка & Скрининг: Crushed material is conveyed to a secondary cone crusher for further reduction. Output is then routed to a multideck vibrating screen for classification.
3. Сортировка продуктов & Накопление запасов: Onspec material from each screen deck is conveyed to designated stockpiles. Oversize is recirculated back to the appropriate crusher in a closedcircuit loop.

Область применения: Ideal for hightonnage production of aggregates for concrete, асфальт, and road base. Подходит для обработки гранита., базальт, известняк, and other abrasive ores.

Ограничения: This is a fixedinstallation solution requiring foundational concrete works and grid power connection. Он не рассчитан на частые переезды..

3. Основные функции: Инжиниринг соответствует операционной рентабельности инвестиций

Модульная структурная рама | Техническая основа: Сборный, hightensile steel sections with machined connection points | Операционная выгода: Включает быстрее, more precise onsite installation with reduced crane time and foundation work | Воздействие на рентабельность инвестиций: Cuts installation timeline by up to 30%, reducing timetorevenue.

Централизованная система управления ПЛК | Техническая основа: Программируемый логический контроллер с человеко-машинным интерфейсом (ЧМИ) панель | Операционная выгода: Allows singleoperator monitoring and control of the entire flow from feeder to final conveyor; provides diagnostic alerts | Воздействие на рентабельность инвестиций: Reduces labor requirements by approximately 1 FTE per shift while improving response time to anomalies.

HeavyDuty Vibrating Screen with QuickDeck Change | Техническая основа: Rubbermounted screen box with tensioned wedgewire or polyurethane panels | Операционная выгода: Minimizes vibration transfer to structure; allows screen media replacement in hours vs. дни | Воздействие на рентабельность инвестиций: Increases annual availability by ~2% and reduces maintenance labor costs.

Crusher Cavity Optimization | Техническая основа: Computeraided design of crushing chamber geometry matched to expected feed material | Операционная выгода: Maximizes reduction ratio per pass, improves product shape (кубичность), and promotes even wear liner utilization | Воздействие на рентабельность инвестиций: Boosts throughput by 515% while extending wear part life cycles.

Пылеподавление & Система сдерживания | Техническая основа: Strategically placed spray nozzles at transfer points with encapsulation skirts | Операционная выгода: Обеспечивает соблюдение нормативных требований по выбросам твердых частиц; protects bearings and motors from dust ingress | Воздействие на рентабельность инвестиций: Avoids regulatory fines and reduces premature bearing failures by an estimated 40%.

Layered Walkways & Платформы обслуживания | Техническая основа: Full perimeter access with safety handrails integrated into the plant design | Операционная выгода: Enables safe visual inspections, routine greasing, and component servicing without specialized scaffolding | Воздействие на рентабельность инвестиций: Promotes proactive maintenance culture; reduces risk of safety incidents and associated downtime/costs.

4. Конкурентные преимущества: Измеримый прирост производительности

| Метрика производительности | Стандартный эталон отрасли | ODM Stationary Plant Solution | Документированное преимущество |
| : | : | : | : |
| Доступность завода (Запланированное время выполнения) | 9092% | 9496%| +4% Улучшение |
| Потребление энергии на тонну переработки| Зависит от типа породы| Optimized motor loads & эффективные приводы| До 12% Снижение |
| Стоимость изнашиваемых деталей за метрическую тонну| $0.85 $1.10 доллар США| Matched chamber design & выбор сплава| 1520% Снижение |
| Установка & Время ввода в эксплуатацию| 810 Недели (from foundation)| Modular frame & предварительно собранные блоки| ~30% Faster (67 Недели)|
| Required Operating Labor per Shift| 34 Personnel| Centralized PLC control system| Reduced by 1 Operator |

5. Технические характеристики

Диапазон расчетной мощности: 200 800 ТПХ (configurable based on model).
Основное требование к питанию: 400В/50 Гц или 480 В/60 Гц; Общая установленная мощность: 350kW 800kW.
Основные характеристики материалов:
Дробильные вкладыши: Марганцевая сталь (14%,18%,22%) or Chrome Iron Alloy options.
Экранные деки:Tensioned Polyurethane or HighCarbon Steel Wire Mesh.
Конвейерная лента:Synthetic Fabric Ply (EP630/3) with minimum 12mm top cover.
Конструкционная сталь:S355JR grade with hotdip galvanized finish on walkways.
Typical Physical Footprint (for a 350TPH plant): ~35 м (л) х 22 м (Вт) х 15 м (ЧАС).
Экологический рабочий диапазон: Ambient temperature 20°C to +45°C; dust emission levels compliant with <10mg/Nm³ standards when used with suppression system.

6. Сценарии применения

Проект расширения гранитного карьера

Испытание:A quarry needed to increase output by over 60% but had limited space for plant expansion within their existing lease boundary.Solution:Компактный,OEMdesigned threestage crushing circuit was installed,fitting into the footprint of an older twostage plant.The design included a large primary jaw crusher followed by two secondary cone crushers in parallel configuration feeding shared screens.This allowed higher throughput without increasing land use.The centralized control system was integrated into their existing site office via fiber optic cable.The new layout reduced internal haulage distances significantly.Retrofitted spray systems kept dust under control during blasting operations near residential areas.Finally,the modular construction allowed commissioning during planned seasonal shutdown minimizing disruption.Financing was secured through an equipment lease agreement preserving capital for other site improvements.Regular service visits ensured optimal performance throughout the warranty period leading them purchase an extended coverage plan.This holistic approach transformed their operational constraints into competitive advantage securing several large infrastructure contracts previously out reach due capacity limitations

Переработка известняка для сырья цементного завода

Испытание:A cement producer required consistent 25mm feed for their raw mill,but variations in quarry moisture content caused frequent clogging in their existing impact crusher.Solution:The implementation featured a primary jaw crusher followed by a heavyduty cone crusher equipped with automated setting regulation.Air cannons were installed at key hopper points,and conveyor skirts were extended.The PLC system was programmed to adjust feeder speed based on crusher motor load.Field data after six months showed clogging events reduced by over95%.Product consistency improved dramatically meeting the 25mm spec99.%of the time.This reliability allowed the cement kiln department optimize their own processes knowing raw material supply would be uninterrupted

Переработка проектов городской инфраструктуры

Испытание:A major road construction project mandated onsite recycling of demolished concrete to reduce truck traffic environmental impact but faced strict noise dust regulations tight urban site.Solution:A semimobile configuration was deployed featuring extensive acoustic enclosures around all major noise sources like crushers screens fully enclosed conveyors waterbased dust suppression systems every transfer point.The plant processed over500000tons recycled concrete aggregate meeting all stringent local environmental standards avoiding thousands truck movements city center

Коммерческие соображения

Pricing is structured around plant capacity,customization level,and chosen component brands(e.g.,crusher motor manufacturer).Мы предлагаем три основных уровня:

1.Базовый уровень конфигурации:Covers core functionality standard components proven reliability suitable budgetconscious operations seeking essential performance.Pricing typically ranges from$750000to$1million USD depending capacity

2.Уровень производительности(Рекомендуется):Includes features like centralized PLC automation premium wear liners enhanced dust suppression walkways platforms.Pricing typically ranges from$ million$ million USD

3.Премиум-уровень «под ключ»:Fully customized solution including advanced predictive monitoring sensors extended warranty comprehensive operator training package civil engineering drawings support.Pricing determined specific project scope

Дополнительные обновления функций:
Advanced vibration monitoring sensors critical bearings
Автоматизированные системы смазки
Overband magnetic separator ferrous metal removal
Additional finished product conveyor stackers
Стартовый комплект запасных частей

Пакеты сервисной поддержки:
Standard Warranty months parts labor excluding wear items
Extended Coverage Plans years available purchase
Annual Maintenance Contracts include scheduled inspections priority technical support discounted spare parts
OnDemand Field Service Technician dispatch available global network partners

Варианты финансирования:
We work accredited financial partners offer:
Equipment leasing structures preserve working capital
Term loans competitive rates project financing
RentaltoOwn programs lower initial commitment

Раздел часто задаваемых вопросов

Что делать, если твердость исходного материала часто меняется??
Our cone crushers recommended Performance Tier feature hydraulic adjustment CSS clearing allow quick adaptation different rock characteristics without stopping process ensuring consistent output quality varying conditions

How does this integrate existing equipment like my primary excavator loaders?
Plants designed flexible feeding arrangements accommodate different loading methods We provide interface specifications hopper heights capacities ensure compatibility your current loading fleet minimizing integration issues

Каков типичный срок поставки при вводе в эксплуатацию??
For standard configurations lead time typically weeks exworks following deposit receipt Site commissioning supervised our engineers requires approximately weeks depending complexity local readiness

Доступны ли запасные части по всему миру??
Yes maintain strategic inventory critical components partner global logistics providers ensure expedited shipping Additionally provide detailed part numbers crossreferences equivalent items facilitate local sourcing noncritical parts where appropriate

Предлагаете ли вы обучение операторов??
Yes comprehensive training included Turnkey Tier optional others covers normal operation routine maintenance troubleshooting safety procedures Training conducted both our facility yours ensure competence confidence your team