1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Управление циклом дробления железной руды представляет собой, highcost challenges. Are you facing persistent bottlenecks that limit your plant’s rated throughput? Is unscheduled downtime for liner changes and component wear eroding your production schedule and maintenance budget? Do you struggle with inconsistent product sizing, leading to downstream processing inefficiencies in grinding or beneficiation? Более того, are rising energy costs per ton of processed material directly impacting your operational margins? Эти проблемы приводят к измеримым потерям.: часы простоя производства, excessive spare parts inventories, and suboptimal resource yield.

Центральный вопрос для руководителей предприятий заключается в следующем.: как можно добиться надежного, hightonnage reduction of abrasive iron ore while controlling capital and operational expenditure? The solution lies in specifying a purposeengineered private label iron ore crushing plant.

2. ОБЗОР ПРОДУКТА

Этот продукт представляет собой полный, modular crushing system engineered for primary and secondary reduction of magnetite, гематит, и другие железосодержащие руды. It is supplied as a private label solution, allowing for branding alignment while leveraging proven, heavyduty componentry.

Операционный рабочий процесс:
1. Первичный дамп & Гризли: Runofmine ore is dumped onto a rugged grizzly feeder, scalping out fine material to bypass the primary crusher, повышение общей эффективности.
2. Первичное щековое дробление: Мощная щековая дробилка выполняет первоначальное измельчение, delivering a consistent feed to the secondary stage.
3. Вторичное конусное дробление: Сердце системы, a highcapacity cone crusher—configured for coarse or mediumfine output—provides the final cubical product sizing critical for downstream processing.
4. Скрининг & ClosedCircuit Control: Sized material is screened; oversize is recirculated back to the cone crusher in a closedloop system ensuring precise final product specification.

Область применения & Ограничения:
Объем: Идеально подходит для установки с нуля или проектов расширения, требующих 500 к 2,500+ Производительность т/ч. Suited for processing hard, abrasive iron ores with compressive strengths up to 350 МПа.
Ограничения: Not designed as a tertiary or quaternary stage for ultrafine grinding. Feed size must conform to crusher opening specifications. Optimal performance requires consistent feed gradation and controlled moisture content to prevent chamber packing.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

HeavyDuty Liner Geometry | Техническая основа: Computermodeled cavity profiles and highchrome white iron metallurgy | Операционная выгода: Extended wear life by 3050% over standard manganese steel in abrasive service | Воздействие на рентабельность инвестиций: Reduces liner change frequency and inventory costs, повышение доступности дробилки.

Advanced Chamber Clearing System | Техническая основа: Hydraulic or gaspowered tramp release and clearing automation | Операционная выгода: Recovers from stall conditions in under 60 секунд без ручного вмешательства | Воздействие на рентабельность инвестиций: Prevents cascading downtime from uncrushable material, protecting downstream conveyor systems.

Централизованная смазка & Управление ПЛК | Техническая основа: Automated lubrication intervals tied to bearing temperature and operating hours | Операционная выгода: Ensures optimal bearing health and eliminates manual greasing errors | Воздействие на рентабельность инвестиций: Увеличивает срок службы основных подшипников до 40%, снижение риска катастрофического отказа.

Модульная конструкция салазок | Техническая основа: Предварительно собранные полозья из конструкционной стали со встроенными переходами и платформами для обслуживания. | Операционная выгода: Reduces onsite civil works and installation time by an estimated 40% | Воздействие на рентабельность инвестиций: Lowers total installed cost (ТИЦ) and accelerates timetoproduction.

Частотно-регулируемый привод (ЧРП) Совместимость | Техническая основа: Crusher motor integration with plantwide process control systems | Операционная выгода: Allows realtime adjustment of crusher speed/throw to match feed conditions for optimal power draw and product shape | Воздействие на рентабельность инвестиций: Achieves energy savings of 1015% under variable load conditions versus fixedspeed operation.

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт (AggregateFocused Plant) | Private Label Iron Ore Solution | Преимущество (% Улучшение) |
| : | : | : | : |
| Срок службы вкладыша (Абразивная руда) | ~450 000 тонн за комплект (Марганец) | ~650,000 tons per set (Special Alloy) | +44% |
| Доступность системы (Запланировано) | ~92% (вкл.. изменения вкладыша) | ~95% (вкл.. изменения вкладыша) | +3 Процентные пункты |
| Потребляемая мощность на тонну переработки| Базовый уровень (100%)| Оптимизированная камера & drive = ~90% of baseline |10% |
| Установка & Время ввода в эксплуатацию| 810 недели на сайте| 56 недели на сайте (модульный)| 30% |
| Штрафы за продукцию (10мм) Контроль| Обычно 1822% продукции| Chamber optimization yields 1518% продукции| 20% reduction in unwanted fines |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Диапазон мощности: Настраивается из 500 TPH превышает 2,500 TPH nominal throughput of taconite ore.
Требования к питанию: Первичная дробилка: 150400 кВт; Вторичная дробилка: 250600 кВт; Total System Feeders/Conveyors/Screens: Additional 300800 кВт в зависимости от конфигурации.
Характеристики материала: Primary wear liners in premium manganese steel; Secondary chamber liners in highchrome white iron (27% Кр). Structural steel is Grade S355JR with abrasionresistant plate in highwear zones.
Физические размеры (Типичный занос): Secondary crushing module approx. L12m x W6m x H7m. Полная площадь установки зависит от конфигурации.
Экологический рабочий диапазон: Designed for ambient temperatures from 25°C to +45°C with optional heating/cooling packages. Dust suppression system integrated as standard.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Расширение фабрики по производству магнетита Greenfield

Испытание:
A major mining operator needed to expand concentrator throughput but was constrained by existing primary crushing capacity producing inconsistent feed size for new SAG mills.
Решение:
Implementation of a turnkey private label iron ore crushing plant as a parallel primary/secondary circuit specifically calibrated for their magnetite ore characteristics.
Результаты:
Достигнут устойчивый рост производительности 1,800 TPH at a consistent 25mm product size. Mill feed stability improved grinding circuit efficiency by an estimated 8%, contributing directly to higher concentrate output.

Lifecycle Replacement in Hematite Operation

Испытание:
An aging fleet of disparate crushers led to high maintenance costs (~20% of annual OPEX), poor availability (94%.

7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Ценовые уровни: Offered across three standardized capacity tiers—Medium Duty (1,800 ТПХ)—with corresponding component specifications.
Дополнительные функции: Upgrades include advanced predictive monitoring sensors (вибрация/температура), automated wear measurement systems, hybrid diesel/electric power modules for remote sites,
and enhanced dust encapsulation packages.
Пакеты услуг: Tiered annual support agreements are available covering scheduled maintenance inspections,
обзор прогнозной аналитики,
and priority parts provisioning with guaranteed dispatch times.
Варианты финансирования: Flexible capital expenditure solutions can be structured including equipment leasing models,
project financing linked to production milestones,
or traditional purchase agreements.

8.Часто задаваемые вопросы

1 квартал:
Are these private label plants compatible with our existing conveying infrastructure?
А1:
Yes.The modular design allows engineering interfaces
(высота разгрузки,
feed chute orientations)
to be customized during the design phase
to integrate with your current stockpile conveyors
or downstream process feed points.Field surveys are conducted
to ensure dimensional compatibility prior
to fabrication

2 квартал:
Каково ожидаемое воздействие на эксплуатацию при вводе в эксплуатацию??
А2:
Our phased commissioning protocol minimizes disruption.Crushing modules are pretested at our facility.Onsite commissioning typically requires two weeks
of planned integration downtime followed by one week
of rampup under supervision until design capacity is met

Q3:
How does the pricing compare
to sourcing major OEM equipment directly?
А3:
The private label model typically offers capital cost savings between fifteen percent without compromising critical component quality.We achieve this through optimized global supply chain logistics
for structural components while utilizing tierone suppliers
for all mechanical drive
and wear parts

Q4:
What are the lead times from order placement
to delivery?
А4:
For standard capacity configurations lead time ranges from twentysix weeks depending on current manufacturing schedule.Complex customizations may extend this timeline which will be defined during project scoping

Q5:
Is training provided for our operations
и бригады технического обслуживания?
А5:
Comprehensive training is included covering safe operation routine maintenance procedures troubleshooting guides specific documentation review conducted both at your site during commissioning

Q6:
Какие условия гарантии применяются?
А6:
The complete structure carries standard warranty.All major mechanical components including crusher main frames shafts bearings motors carry manufacturer warranties which we manage on your behalf providing singlepoint support

Q7:
Can this plant handle variations in ore hardness within our deposit?
A7：
The hydraulic adjustment systems on both jaw cone crushers allow operators adjust closed side settings compensate variations hardness maintain consistent product size PLC control system can automate adjustments based power draw maintaining optimal performance across different ore zones