Crushing And Screening Equipment Producers Cheap
1. PAINPOINT driven اوپننگ
آپريشنل خرچن کي وڌائي رهيا آهن ۽ غير متوقع بند وقت توهان جي پروجيڪٽ جي مارجن کي ختم ڪري رهيا آهن? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, ڪرشنگ ۽ اسڪريننگ سرڪٽ اڪثر ڪري نازڪ رڪاوٽن جو ذريعو آهي. عام چئلينج شامل آهن:
اعلي سار سنڀال خرچ: بار بار بيئرنگ ناڪامي, اسڪرين ڪپڙي جي تبديلي, and conveyor belt wear from improper material flow can consume 1520% of your annual operating budget.
اڻ شيڊول بند وقت: A primary crusher failure or screen box structural issue can halt an entire site, costing tens of thousands per hour in lost production and labor.
Inefficient Material Flow: Poorly matched equipment leading to recirculating loads, chokefeeding, or underutilization reduces overall system capacity by up to 30%.
متضاد پيداوار جي درجه بندي: Offspec aggregate or mineral product results in costly recrushing, stockpile segregation issues, and rejected loads.
وڌندڙ توانائي واپرائڻ: پراڻو, mechanically inefficient drives and components directly increase your kWhperton cost, a key metric under constant pressure.
Is your operation equipped to minimize these risks while maximizing throughput and product quality? The foundation lies in selecting robust, intelligently engineered crushing and screening equipment.
2. پيداوار جو جائزو
This content outlines the critical considerations for stationary and trackmounted crushing and screening equipment, the core machinery for reducing raw feed material (مثال, quarry rock, ٻيهر استعمال ٿيل ڪنڪريٽ, mineral ore) مخصوص مجموعي سائزن ۾. آپريشنل ڪم فلو هڪ مسلسل عمل آهي:
1. پرائمري سائيز جي گھٽتائي: Large feed material is reduced by jaw or gyratory crushers.
2. Material Transport & اسڪيلنگ: Conveyors move material to vibrating screens that remove undersize material prior to secondary crushing.
3. ثانوي / ٽيٽيري ڪرشنگ: Cone or impact crushers further reduce material to required dimensions.
4. فائنل اسڪريننگ & ترتيب ڏيڻ: Multideck screens accurately separate crushed material into precise product fractions (مثال, ¾” chip, ٺاهيل ريت).
5. ذخيرو ڪرڻ & ReCirculation: Onspec product is conveyed to stockpiles; oversize material is recirculated back into the circuit.
درخواست جي دائري ۾ کوٽائي شامل آهي, کان کني, اڏاوت & تباهي ري سائيڪلنگ, ۽ مجموعي پيداوار. Key limitations involve feed material abrasiveness (impacting wear life) ۽ حتمي پيداوار جي وضاحتن جي ضرورت آهي (dictating circuit design).
3. بنيادي خاصيتون
پيٽرن ٿيل چيمبر جاميٽري | ٽيڪنيڪل بنياد: Computermodeled kinematics and cavity profiles | آپريشنل فائدا: Optimized nip angle and crushing stroke for higher reduction ratios with less wear on manganese surfaces | ROI اثر: تائين 12% lower costperton in abrasive applications due to extended liner life.
ماڊلر اسڪرين ميڊيا سسٽم | ٽيڪنيڪل بنياد: Quicktensioning wedgelock design with polyurethane damping | آپريشنل فائدا: Screen deck changes completed in under 2 hours versus a typical 68 hour shift, with consistent tension for longer cloth life | ROI اثر: Reduces labor hours for maintenance by ~70% per changeout, پلانٽ جي دستيابي کي وڌائڻ.
مرڪزي گريسنگ & حالتن جي نگراني | ٽيڪنيڪل بنياد: Automated lube points with flow sensors feeding a central PLC | آپريشنل فائدا: Ensures critical crusher and screen bearings receive precise lubrication without manual intervention; alerts operators to blockages | ROI اثر: Prevents an estimated 85% of bearingrelated failures, avoiding associated downtime costs.
Hybrid Power Drive System | ٽيڪنيڪل بنياد: Dieselelectric configuration with onboard genset or external grid connection capability | آپريشنل فائدا: Operators can select the most costeffective power source; electric mode reduces fuel consumption by 100% when grid power is available | ROI اثر: Field data shows average energy cost savings of 2540% in hybrid mode versus dieselonly operation.
HeavyDuty Feeder with PreScreening Section | ٽيڪنيڪل بنياد: Grizzly feeder with integrated stepped grizzly bars or punch plate section | آپريشنل فائدا: Removes natural fines and subproduct size material before the primary crusher, reducing chamber volume usage and wear | ROI اثر: Increases effective primary crusher throughput by up to 15% by eliminating precrushed material.
Reinforced Structural Frame Design | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي) optimized steel fabrication with highstress zone reinforcements | آپريشنل فائدا: Withstands continuous highcycle loading without frame fatigue or cracking common in highproduction environments | ROI اثر: Eliminates unplanned structural repairs, protecting asset lifespan over a 15+ year service period.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري معيار | اسان جي ڪرشنگ & Screening Solution Documented Performance | فائدو (% سڌارو) |
| : | : | : | : |
| Crusher Liner Wear Life (ابراھيندڙ پٿر) | ~450,000 tons per set (Cone Crusher Mn18) | ~520,000 tons per set (Proprietary Mn22 Alloy) | +15% Longer Life |
| Screen Box Sideplate Vibration Fatigue Failure Mean Time Between Failure (ايم بي ايف) | ~8,000 operating hours before weld repair required| >14,000 operating hours before inspection advised| +75% Improved Durability |
| توانائي جو واھپو (kWh per Ton Processed) Baseline for a 300tph Circuit| ~0.85 kWh/Ton Average| ~0.72 kWh/Ton Documented Average| 15% گھٽ توانائي جي قيمت |
| ملڪيت جي ڪل قيمت (ٽي سي او) مٿان 5 Years (سار سنڀال + حصا + بند وقت)| Indexed at 100% مقابلي لاءِ| Estimated at 7882% of benchmark TCO| 18% جي طرف 22% Lower TCO |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: اسٽيشنري ٻوٽن مان 150 ختم ڪرڻ 1,200 ٽين في ڪلاڪ (ٽي پي ايڇ). Trackmounted mobile units from 200 جي طرف 500 ٽي پي ايڇ.
بجلي جي گهرج: Primary crushing units typically require 150400 kW drives. Full electric stationary plants may require a total connected load of 8002,500 kVA depending on scale.
مواد جي وضاحت: Fabricated from S355JR structural steel; highwear components utilize HB500 abrasionresistant steel liners; crusher jaws/cones in premium manganese steel (Mn18Cr2/Mn22Cr2).
جسماني طول و عرض (Example Mobile Unit): Transport length approx.16m; Operating length approx.19m; Max height approx.4m; Operating weight approx.45 tonnes.
ماحولياتي آپريٽنگ رينج: 25 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; dustprotected بيرنگ (IP65+); capable of operating at altitudes up to 3,000 meters with engine deration.
6. درخواست جا منظر
گرينائيٽ ڪواري توسيع پروجيڪٽ
Challenge A major quarry needed to increase production by 40% without expanding their permitted footprint or adding a second processing shift.
Solution Implementation of a new tertiary crushing stage featuring a highspeed cone crusher paired with a tripledeck fine screen in closed circuit.
Results Achieved target throughput increase within existing footprint. The closedcircuit design reduced recirculating load by over half compared to the old layout while improving cubicity of the chip products.
شهري سي&D Recycling Operation
Challenge Processing highly variable construction demolition waste led to frequent jamming in the primary impact crusher from uncrushable rebar matts and excessive fines clogging screens.
Solution Deployment of a heavyduty jaw crusher as primary stage for better tramp metal tolerance and an aggressive linear stroke screen ahead of secondary processing for fines removal.
Results Unplanned stoppages due to feeding issues decreased by approximately90%. The removal of fines early in the circuit significantly improved efficiency of downstream sorting equipment.
7 تجارتي خيالات
Equipment pricing tiers are structured around capacity capability:
ٽائر I (600 ٽي پي ايڇ): Customengineered stationary crushing and screening plants.
Optional features include advanced dust suppression systems automated metal detection/ ejection magnetic head pulleys extended conveyor systems
Service packages range from basic warranty support through comprehensive multiyear maintenance agreements including scheduled parts kits
Financing options are available including capital lease operating lease commercial loans tailored
8 FAQ
What level of ground preparation is required for installing this equipment?
Stationary plants require engineered concrete foundations Mobile track mounted units require stable compacted ground but minimal civil work enabling rapid redeployment
How does your equipment interface with our existing conveyors stackers?
Our engineering team provides detailed interface specifications for chute heights discharge trajectories belt widths ensuring compatibility
آرڊر ڪميشننگ کان عام ليڊ ٽائيم ڇا آهي?
For standard mobile units lead time is typically weeks For large custom stationary plants detailed engineering procurement fabrication requires months
ڇا توهان ڪارڪردگي جي ضمانت فراهم ڪندا آهيو?
Yes we offer guaranteed minimum capacity based on agreed feed material specifications Guarantees are backed by pre purchase material testing circuit simulation
What operator training technical support do you provide?
We include comprehensive onsite training for operations maintenance crews along with digital manuals Access remote diagnostic support via data link standard
