1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Are you managing a stone quarry operation where profit margins are consistently pressured by equipment performance? The challenges of primary crushing are often the bottleneck. Учитывайте эти общие эксплуатационные препятствия:
Чрезмерное время простоя для технического обслуживания: Частая смена вкладышей, неожиданные поломки подшипников, and wear part replacement halt your entire production line, потери дохода в тысячи долларов в час.
Непостоянный размер корма & Пропускная способность: Преодоление, сегрегация, and irregular feed from the quarry face lead to poor crusher cavity fill, reducing capacity and increasing wear unevenly.
Высокие эксплуатационные расходы: Резкий рост потребления энергии на тонну перерабатываемого материала, coupled with the high and frequent cost of wear parts like mantles, вогнутый, и челюстные пластины, directly erode profitability.
Несоответствие качества продукции: Inability to reliably control topsize output or an excessive proportion of flaky material can impact downstream processes and final product marketability.
Безопасность & Accessibility Concerns: Routine inspections and maintenance tasks that are timeconsuming or require personnel to work in hazardous proximity to the equipment.

Является ли ваша основная дробильная станция источником надежности или центром постоянных затрат?? The right contract manufacturer for your stone quarry crushing plant addresses these issues at the design phase, focusing on total cost of ownership rather than just initial purchase price.

2. ОБЗОР ПРОДУКТА

This content outlines the critical considerations for a stationary primary jaw crusher station within a complete stone quarry crushing plant. Designed as the first mechanical reduction stage, this system is engineered for high availability and low costperton in hard rock applications like granite, базальт, и известняк.

Операционный рабочий процесс:
1. Потребление корма: Dump trucks or wheel loaders discharge runofquarry (ROQ) material into a rugged vibrating grizzly feeder (ВГФФ ВГФ).
2. Предварительный скрининг & Удаление штрафов: The VGF scalps out natural fines and subcrushsize material via its grizzly bars, bypassing the crusher to increase efficiency and reduce wear.
3. Первичное сокращение: Oversize material is conveyed into the jaw crusher cavity, where compressive force between a fixed and a moving jaw plate fractures the rock.
4. Увольнять & Транспортировка: Дробленый материал выгружается на главный конвейер продукта для транспортировки на вторичное дробление или складирование..

Область применения & Ограничения:
Объем: Идеально подходит для крупнотоннажных перевозок, abrasive hard rock quarries requiring a robust primary breaker. Optimal for material with compressive strength up to 400 МПа.
Ограничения: Не подходит для липких, глинистые материалы без предварительной обработки. A gyratory crusher may offer superior throughput for capacities exceeding 1,500 tph in certain configurations.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Вибрационный колосниковый питатель HeavyDuty (ВГФФ ВГФ) | Техническая основа: Highstrength steel plate construction with boltin AR liners | Операционная выгода: Regulates feed rate to the crusher, eliminates bridging, removes fines to prevent crusher packing | Воздействие на рентабельность инвестиций: Increases effective crusher capacity by up to 15% and reduces unnecessary wear on crusher components

WedgeBased Jaw Plate Adjustment System | Техническая основа: Mechanically locked wedges replace traditional shim plates | Операционная выгода: Включает безопасный, fast CSS adjustment and jaw plate changes from the crusher’s nondrive side in under two hours | Воздействие на рентабельность инвестиций: Reduces downtime for routine adjustments by approximately 60%, максимизация продуктивного рабочего времени

Оптимизированная геометрия дробильной камеры | Техническая основа: Компьютерное моделирование кинематики и угла захвата | Операционная выгода: Promotes deepbed crushing throughout the chamber for consistent particleonparticle breakage | Воздействие на рентабельность инвестиций: Produces a more cubical product shape (improving secondary crush efficiency) and extends jaw plate service life by distributing wear more evenly

Интегрированная моторная база & Ремень Защитный | Техническая основа: Unified steel fabrication housing crusher motor(с) и водить охрану | Операционная выгода: Eliminates complex field alignment during installation; обеспечивает безопасный, integral guarding compliant with site safety standards | Воздействие на рентабельность инвестиций: Сокращает время и стоимость установки до 30%, ensuring faster commissioning

Централизованные точки смазки & Порты мониторинга состояния | Техническая основа: Lube lines routed to accessible groundlevel stations with ports for vibration/temperature sensors | Операционная выгода: Enables daily lubrication and health checks without operators needing to access elevated platforms near moving parts | Воздействие на рентабельность инвестиций: Enhances preventative maintenance adherence, improving bearing life and preventing catastrophic failures

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт | Наше решение для дробильных установок для каменных карьеров | Преимущество (% Улучшение) |
| : | : | : | : |
| Время замены вкладыша | 68 часы (Челюстные пластины) | < 2 часы (Челюстные пластины) | ~70% быстрее |
| Энергоэффективность| 0.85 1.1 кВтч/тонна переработки| Цель: 10% улучшение |
| Наличие дробилки| ~9294% (запланировано & внеплановый)| Цель проекта: >96%| ~34% увеличение |
| Wear Part Utilization| ~6070% of theoretical weight used before changeout| Design enables use of >85% of liner mass| ~25% better utilization |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Ссылка на модель: STQPrimary1442HD
Тип дробилки: Щековая дробилка HeavyDuty с одним рычагом
Кормовое отверстие: 1400мм х 1100 мм (55" х 42")
Максимальный размер подачи: 1000мм (40") длина кромки
Закрытая боковая установка (CSS) Диапазон: 150мм 300 мм (6" 12")
Диапазон мощности: 450 850 метрика т/ч (dependent on feed gradation & CSS)
Требования к мощности привода: 200 кВт (275 HP), electric motor with softstart compatibility
Total Plant Power Demand (Feeder/Crusher/Conveyors): Приблизительно. 350 кВт
Основные характеристики материалов: Основная рама изготовлена ​​из стальной пластины; Jaw plates Manganese steel alloy; Shaft forged alloy steel; Подшипники сферические роликовые.
Приблизительная площадь (Д х Ш): 18m x 8m
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 20°С до +45°С.; пылезащитные подшипники; weather protection covers standard.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Проект расширения гранитного карьера

Испытание: An existing granite quarry needed to expand production but was constrained by an aging primary plant causing over 40 hours of unplanned downtime monthly due to reliability issues.
Решение: Contract design and supply of a complete new primary stone quarry crushing plant station built around a heavyduty jaw crusher with enhanced accessibility features.
Результаты: Postinstallation data showed plant availability increased from 88% к 96%. Unplanned downtime was reduced by over 90%, enabling the site to meet its expanded production target within six months.

Basalt Aggregate Producer Seeking Cost Control

Испытание: A producer faced volatile profitability due to uncontrollably high energy costs per ton and rapid wear part consumption in their primary stage.
Решение: Implementation of an optimized plant design featuring chamber geometry focused on energyefficient breakage and a feeder system that removed more fines prior to crushing.
Результаты: Field data tracked over one year showed a reduction in specific energy consumption from 0.98 kWh/ton to 0.82 kWh/ton—a direct utility cost saving—and extended average jaw plate life by approximately 22%.

7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Our approach as your contract manufacturer is based on transparent value engineering:

Ценовые уровни
1. Standard Plant Package includes core equipment as specified above with basic walkways/platforms.
2.Optimized Plant Package includes additional features such as dust suppression system integration advanced condition monitoring sensor packages automated grease systems (+1015%)
3.Turnkey Project Package includes full civil design support installation supervision commissioning services (+варьируется)

Optional Features include metal detection systems tramp iron relief automation hydraulic setting adjustment vs manual modular skid designs for faster relocation

Пакеты услуг:
• Commissioning Support Onsite training operational readiness review
• Planned Maintenance Contracts Guaranteed parts supply scheduled inspections fixed annual cost models
• Performance Audits Annual review of throughput wear rates efficiency recommendations

Financing Options available through our partners include capital lease operating lease longterm rentaltoown structures tailored typically over 3 7 10условия года

8.Часто задаваемые вопросы

Q What if my current secondary crushers are not from your company? Is compatibility an issue?
A No Our stone quarry crushing plant is designed as an independent modular station Output specifications including product size distribution are engineered based on your input requirements ensuring seamless interface with any downstream equipment via proper transfer conveyors

Q How does this solution address my high energy costs?
A Energy efficiency is engineered into multiple components including optimized feedercrusher interaction efficient drive motor selection correctly sized gearboxes The overall system design aims minimize bottlenecks that cause motors run underloaded which inefficient Field data shows our optimized plants typically achieve measurable reductions specific energy consumption kWh per ton processed

Q What guarantees do you provide on performance metrics like throughput?
A We provide process performance guarantees based agreedupon feed material characteristics These are detailed commercial terms within contract specifying test methods duration We guarantee mechanical performance structural integrity workmanship standard industryleading warranties major components

Q Can you accommodate limited space on my existing site?
A Yes As contract manufacturer we specialize designing plants fit constrained layouts offering modular configurations vertical arrangements reduce footprint compared traditional horizontal flow designs Detailed layout studies conducted during proposal phase ensure feasibility before commitment made

Q What typical lead time expected from contract signing delivery?
A For standard configured stone quarry crushing plant lead times typically range 6 9 months depending complexity current manufacturing schedule Expedited options may available additional cost Longlead items like castings forgings identified early process