Fda Approved Iron Ore Crushing Plant Private Label Manufacturer
1. PAINPOINT driven اوپننگ
لوھ لوھ جي ڪرشنگ سرڪٽ جو انتظام الڳ پيش ڪري ٿو, قيمتي چئلينج. Are you experiencing persistent bottlenecks that limit your plant’s rated throughput? Are unscheduled maintenance stops and premature wear part failures eroding your operating budget and creating unpredictable downtime? Is inconsistent product sizing leading to inefficiencies in downstream grinding and processing, ultimately affecting pellet or sinter quality? ان کان سواء, does the total cost of ownership for your primary crushing stage—factoring in energy consumption, liner replacements, and labor—exceed initial projections? These operational hurdles directly impact profitability. پلانٽ مينيجرز لاءِ مرڪزي سوال هي آهي: توهان ڪيئن قابل اعتماد حاصل ڪري سگهو ٿا, hightonnage reduction of abrasive iron ore while controlling operational costs and maximizing plant availability?
2. پيداوار جو جائزو
هي پيداوار هڪ آهي پرائمري Gyratory کولہو engineered specifically for highcapacity iron ore processing. It is designed as the first critical stage in a mineral processing plant, receiving runofmine (روم) feed directly from the pit.
آپريشنل ڪم فلو:
1. کاڌ خوراڪ: ROM لوهه جي معدنيات (1.5 ميٽر جي ماپ تائين) is dumped into the crusher’s deep, nonchoking وصولي hopper.
2. ڇڪڻ وارو عمل: A centrally mounted mantle gyrates within a concave bowl, applying compressive force to break the ore against itself.
3. خارج ٿيڻ: Crushed material exits through the bottom setting (سي ايس ايس), with product size typically ranging from 150mm to 250mm for feed to secondary crushing or SAG mill circuits.
ايپليڪيشن جو دائرو & حدون:
دائرو: Ideal for largescale mining operations with high daily tonnage requirements (>10,000 MTD). Suited for processing hard, abrasive hematite and magnetite ores.
حدون: Not designed for final product sizing or for processing materials with high clay or moisture content without adequate prescreening/scalping. تنصيب ۽ سار سنڀال لاءِ هڪ مستحڪم ڪنڪريٽ بنياد ۽ اهم هيڊ روم جي ضرورت آهي.
3. بنيادي خاصيتون
Patented Concave ڊيزائن | ٽيڪنيڪل بنياد: ورهايل, reversible alloy steel segments | آپريشنل فائدا: تائين سروس جي زندگي کي وڌائي ٿو 30% by allowing rotation and use of multiple wear surfaces before replacement | ROI اثر: Reduces liner inventory costs and downtime for concave changes
ضم ٿيل خودڪار سيٽنگ ريگيوليشن | ٽيڪنيڪل بنياد: پوزيشن سينسر سان هائيڊولڪ ترتيب ڏيڻ وارو نظام | آپريشنل فائدا: Allows operators to adjust the crusher discharge setting in minutes without stopping the process | ROI اثر: Maintains optimal product size for downstream efficiency, increasing overall circuit throughput by an estimated 25%
حالت جي نگراني سان ليوب سسٽم | ٽيڪنيڪل بنياد: Dualcircuit filtration and temperature/pressure sensors feeding to plant DCS | آپريشنل فائدا: Provides continuous protection of critical bearings; alerts personnel to potential issues before failure occurs | ROI اثر: Prevents catastrophic bearing damage, a failure that can result in over 200 گم ٿيل پيداوار جا ڪلاڪ
SpiderMounted Dump Hopper & Seal | ٽيڪنيڪل بنياد: Reinforced design with multistage dust seal system | آپريشنل فائدا: Effectively contains dust at the feed point and prevents contaminant ingress into the main bearing assembly | ROI اثر: Reduces environmental emissions compliance costs and extends bearing life in dusty conditions
HeavyDuty مين شافٽ ڊيزائن | ٽيڪنيڪل بنياد: Forged alloy steel shaft with optimized fatigue resistance profile | آپريشنل فائدا: Provides exceptional strength to handle tramp steel and uncrushable material events without shaft deflection or failure | ROI اثر: Eliminates unplanned outages related to shaft failure, a primary cause of extended downtime in primary crushing
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (مقابلي جي اوسط) | This Primary Gyratory Crusher Solution | فائدو (% سڌارو) |
| : | : | : | : |
| دستيابي (مقرر ڪيل وقت) | 9294% | 96%+ documented field average over 24 مهينا | ~ 34٪ بهتري |
| لائنر زندگي (Million Tons/Set) Hematite Ore| 4.5 5.5 Mtons | 6.0 7.0 Mtons verified at multiple sites| ~1520% واڌارو |
| مخصوص توانائي واپرائڻ (kWh/ٽن) | 0.18 0.22 kWh/t | 0.15 0.17 kWh/t based on installed motor vs. throughput data| ~18% improvement |
| Tramp Iron PassThrough Recovery Time| دستي صاف ڪرڻ; بند ٿيڻ جا ڪلاڪ| Hydraulic clearing system; 80% reduction in event duration |
5. ٽيڪنيڪل وضاحتون
ماڊل نامزدگي: PGC60110
فيڊ کولڻ: 1,520 ايم ايم (60 انچ)
نامياتي ظرفيت جي حد: 3,500 7,500 mtph (dependent on ore characteristics and discharge setting)
انسٽال ٿيل پاور: 600 ڪلواٽ (800 ايڇ پي) electric drive motor
مکيه شافٽ: Forged ES355 alloy steel
مقدر & Mantle Material: ASTM A128 Manganese Steel with proprietary heat treatment
ڪل وزن (صرف کولہو): ~275 metric tons
Top Shell Diameter: ~4.8 meters
آپريٽنگ جي درجه حرارت جي حد: 30°C کان +45°C (with appropriate lube oil specifications)
مٽي ڪنٽرول: Integral connection points for plant dust extraction system.
6. درخواست جا منظر
LargeScale Open Pit Mine – Australia Challenge:
A major hematite operation faced declining feed grades, requiring higher throughput volumes through their primary crushing station to maintain annual production targets. Their existing crusher was unable to achieve higher tonnage without excessive wear and energy costs.
حل:
Implementation of one PGC60110 Primary Gyratory Crusher with the integrated automatic setting system.
نتيجا:
Within six months of commissioning:
Sustained throughput increased by 18%, meeting upgraded plant demands.
Energy cost per ton crushed decreased by 16%.
Annual planned maintenance hours were reduced by 120 hours due to extended liner intervals.
Magnetite Concentrator – North America Challenge:
The client’s new greenfield project required a primary crusher capable of handling extremely hard magnetite ore while guaranteeing >95% availability as the single point of failure for the entire coarse ore circuit.
حل:
Installation of two PGC60110 crushers configured with full condition monitoring on lube systems and main bearings.
نتيجا:
Over the first two years of operation:
Achieved an average operational availability of 96.7%.
Successfully passed multiple tramp metal events without damage via the hydraulic release system.
Condition monitoring provided actionable data that allowed scheduling of a bearing inspection during a planned plant shutdown, avoiding a predicted inservice failure.
7 تجارتي خيالات
Our commercial model is structured around providing predictable total cost outcomes.
سامان جي قيمت جا درجا: Pricing is based on configuration.
بنيادي جوڙجڪ: Core crusher assembly with standard lubrication unit.
ترقي يافته ترتيب: Includes automatic setting regulation (ASR), ترقي يافته حالت جي نگراني sensors, and upgraded dust sealing.
Turnkey SkidMounted Unit: Crusher preassembled on a structural skid base with walkways, ڏاڪڻيون, and integrated lubrication system for faster installation.
اختياري خاصيتون & واڌارو: Wear monitoring systems via concave wear sensors; premium ceramic composite liners for specific abrasion zones; custom discharge conveyor flanges; extended warranty packages on major castings.
سروس پيڪيجز:
رٿيل سار سنڀال جو معاهدو: مقرر ڪيل چڪاس, oil analysis programs, ۽ ٽيڪنيڪل سپورٽ.
Liner Service Contract: Guaranteed liner life performance with fixedcostperton replacement parts.
مڪمل خدمت جو معاهدو: سڀني حصن کي ڍڪي ٿو (پائڻ & مشيني), محنت, and field service engineering for a fixed annual fee.
فنانسنگ جا اختيار: We offer several capital solutions including traditional equipment financing/leasing through our partners or performancebased contracting models where payments can be partially linked to achieved availability or throughput guarantees.
8 FAQ
1.Q What is the lead time from order placement to delivery?
A For standard models like the PGC60110 lead times are typically between 912 months due to extensive forging and machining requirements for major components like the main shaft and top shell castings
2.Q How does this crusher integrate with our existing PLC/SCADA control system?
A The unit comes standard with an AllenBradley ControlLogix PLC local panel All critical operational data pressure temperature motor status ASR position are communicated via industrystandard Modbus TCP/IP or Ethernet/IP protocols allowing straightforward integration into your wider plant control network
3.Q What are your recommendations regarding feed size distribution?
A For optimal performance we recommend ROM feed where no more than XNUMX% exceeds XNUMX times the nominal feed opening size Consistent feeding using a vibrating grizzly feeder or apron feeder is critical Our engineering team can review your specific mine plan geology data
4.Q Do you provide installation supervision?
A Yes we offer optional expert field service supervision during installation commissioning This service ensures correct mechanical alignment electrical connection verification lubrication system flushing procedure adherence which directly impacts longterm reliability
5.Q What are typical spare parts inventory recommendations?
A We provide sitespecific recommendations based on your operating schedule However we maintain regional stockholding centers globally offering XNUMX/XNUMX emergency parts dispatch Critical spares like main shaft step washers eccentric bushings should be held onsite per our recommended list
6.Q Can you guarantee performance metrics like capacity or liner life?
A Formal performance guarantees are provided as part of our commercial proposal following detailed review analysis of your representative ore samples geotechnical data These guarantees form part binding contract subject defined test protocols postcommissioning
