لوھ لوھ جي ڪريشنگ پلانٽ جي ٺيڪيدار ٺاهيندڙ سرٽيفڪيٽ
1. PAINPOINT driven اوپننگ
ڇا توھان منظم ڪري رھيا آھيو غير متوقع throughput, زيادتي لائنر پائڻ جي قيمت, and unplanned downtime in your primary crushing circuit? In iron ore processing, suboptimal primary crushing creates bottlenecks that ripple through your entire operation, directly impacting pellet and sinter feed consistency. اهم چئلينج شامل آهن:
هاء Abrasion خرچ: Constant exposure to hard, abrasive hematite or magnetite leads to premature crusher liner failure. اهو نتيجو اڪثر ڪري ٿو, costly shutdowns for replacement and significant consumable expenditure.
اڻ سڌيءَ طرح: An illsuited or aging primary crusher cannot maintain a steady feed to downstream grinding circuits, causing process instability and limiting overall plant capacity.
اڻ شيڊول بند وقت: Mechanical failures in critical components under high stress lead to catastrophic stoppages, jeopardizing production targets and maintenance budgets.
Size Distribution Issues: Inconsistent product sizing from the primary stage increases the load and energy consumption on secondary and tertiary crushers, raising your cost per ton.
Is your current solution equipped to handle the specific impact and abrasion of iron ore? Can you quantify your true cost of ownership from liner changes and energy use? The foundation of an efficient mineral processing plant begins with reliable, heavyduty primary comminution.
2. پيداوار جو جائزو
Our engineered solution is a turnkey Iron Ore Crushing Plant Contract, centered on robust, highcapacity primary gyratory or jaw crushers specifically configured for dense, abrasive ironbearing rock. We deliver a complete system from runofmine (روم) receiving to a defined crushed product for secondary processing.
آپريشنل ڪم فلو:
1. ROM وصول ڪرڻ & پري اسڪريننگ: Dump pocket or apron feeder receives direct haul truck feed. Grizzly screening removes subfines to bypass the crusher, ڪارڪردگي بهتر ڪرڻ.
2. پرائمري ڪرشنگ: The core heavyduty crusher reduces large lump ore (1.5m تائين) to a manageable product size (عام طور تي 250mm).
3. مواد سنڀالڻ: Robust belt conveyors with impactresistant idlers transport crushed material.
4. ذخيرا يا سڌو فيڊ: Crushed ore is either stockpiled for blending or conveyed directly to the next stage of the beneficiation circuit.
ايپليڪيشن جو دائرو & حدون:
دائرو: Ideal for greenfield installations or brownfield upgrades requiring highcapacity (2,000 10,000+ tph), continuousduty primary crushing of hard iron ores.
حدون: Not designed for final product sizing; requires secondary/tertiary stages for fine crushing. Sitespecific geotechnical conditions must be evaluated for foundational support.
3. بنيادي خاصيتون
HeavyDuty Manganese Liners | ٽيڪنيڪل بنياد: Workhardening austenitic manganese steel | آپريشنل فائدا: Liners develop a hardened surface layer during operation that resists cutting and gouging from abrasive ore | ROI اثر: فيلڊ ڊيٽا ڏيکاري ٿو a 2035% increase in liner life compared to standard alloys, reducing part cost and changeout frequency.
هائيڊرو سيٽ سي ايس ايس ايڊجسٽمينٽ | ٽيڪنيڪل بنياد: Hydraulic cylinder controls the crusher's closedside setting (سي ايس ايس) | آپريشنل فائدا: Operators can adjust product size or compensate for wear remotely under load in minutes | ROI اثر: Maintains optimal throughput and product gradation without stopping production, maximizing crusher utilization.
انٽيگريڊ ٽرام لوھ تحفظ | ٽيڪنيڪل بنياد: Hydraulic relief cylinders with automatic reset | آپريشنل فائدا: خودڪار طور تي ناقابل برداشت مواد جاري ڪري ٿو (مثال, بالٽي ڏند, ڊرل بٽس) to prevent catastrophic damage to the main shaft and head | ROI اثر: Eliminates risk of major mechanical failure and associated weekslong downtime; protects core asset integrity.
Advanced Bearing Design | ٽيڪنيڪل بنياد: Largediameter spherical roller bearings with circulating oil lubrication | آپريشنل فائدا: Supports extreme radial loads and delivers reliable performance under shock loading from large feed blocks | ROI اثر: صنعت جي جاچ ڏيکاري ٿو بيئرنگ سروس جي زندگي کان وڌيڪ 50,000 hours under proper maintenance, ensuring longterm reliability.
PLC جي بنياد تي ڪنٽرول & نگراني نظام | ٽيڪنيڪل بنياد: Centralized programmable logic controller with vibration sensors and temperature monitors | آپريشنل فائدا: بيئرنگ صحت تي حقيقي وقت ڊيٽا مهيا ڪري ٿي, لوڻ جي حالت, and power draw for predictive maintenance scheduling | ROI اثر: Enables conditionbased maintenance planning over fixed schedules, preventing failures and optimizing component replacement cycles.
Modular Plant Design Philosophy | ٽيڪنيڪل بنياد: Preengineered structural modules for major assemblies (crusher base, رستا, conveyor سيڪشن) | آپريشنل فائدا: Reduces field fabrication time by up to 40%, accelerating commissioning schedules in remote locations | ROI اثر: Lowers total installed cost through reduced onsite labor hours and gets your revenuegenerating asset operational faster.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | Industry Standard Baseline | اسان جو لوهه لوهه جي ڪرشنگ پلانٽ حل | فائدو (% سڌارو) |
| : | : | : | : |
| لائنر زندگي (Abrasive Hematite) | ~1.2 Million MT per set (بيس لائين) ~1.6 Million MT per set (بيس لائين) ~92% Uptime (بيس لائين) ~0.12 kWh/tonne (بيس لائين) ~8 Weeks OnSite Erection Time (بيس لائين)| >1.6 Million MT per set >95% اپٽائم <0.10 kWh/tonne <5 Weeks OnSite Erection Time| +33% +15% +17% 37%|
| دستيابي (مقرر ڪيل وقت) |
| مخصوص توانائي واپرائڻ |
| تنصيب & ڪميشن جي مدت |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 2,500 ختم ڪرڻ 9,000 ٽين في ڪلاڪ (tph), based on ore density (~2.8 t/m³), فيڊ جي سائز جي تقسيم, ۽ گهربل گھٽتائي جو تناسب.
پرائمري کولہو جا اختيار: Gyratory Crushers (54"75" فيڊ کولڻ) or HeavyDuty Jaw Crushers.
بجلي جي گهرج: مکيه کولہو ڊرائيو موٽر کان 300 kW تائين 750 ڪلواٽ; ڪل پلانٽ سان ڳنڍيل لوڊ ترتيب جي لحاظ کان مختلف آهي.
مواد جي وضاحت: پريميئم گريڊ مينگنيز اسٽيل ۾ کولہو لائنر; structural steelwork compliant with international standards; conveyor belts rated for highimpact MSHA applications.
جسماني طول و عرض: Plant footprint is sitespecific but typically requires an area of approximately 40m x 60m including feed hopper discharge conveyor runoff.
ماحولياتي آپريٽنگ رينج: Designed for ambient temperatures from 30°C to +50°C with appropriate lube oil heaters/coolers; dust suppression systems are standard.
6. درخواست جا منظر
گرين فيلڊ ميگنيٽائٽ ڪنسٽرٽر پروجيڪٽ
چيلنج: A new mine required a primary crushing circuit capable of processing highly abrasive magnetite at 6,500 tph with >94% availability to meet stringent downstream grinding mill feed schedules.
حل: Implementation of a turnkey iron ore crushing plant contract featuring a large gyratory crusher with automated setting adjustment and modular construction.
نتيجا: پلانٽ ڪم ٿيڻ جي ٻن هفتن اندر نيم پليٽ جي گنجائش حاصل ڪري ورتي. Availability averaged 96.2% in the first year of operation against a contractual target of 94%. Modular build reduced onsite construction labor costs by an estimated USD $350k.
براون فيلڊ هيماتائٽ پروسيسنگ اپ گريڊ
چيلنج: An existing operation faced escalating costs due to bimonthly liner changes in their old jaw crusher and inconsistent feed size causing bottlenecks in SAG mill throughput.
حل: Replacement with our modern gyratorybased iron ore crushing plant solution designed for higher throughput with superior wear life.
نتيجا: Liner life extended from approximately 60 days to an average of 85 days—a direct reduction in consumable costs by nearly onethird per annum—while providing a more consistent 200mm product that improved SAG mill stability by approximately eight percent as measured by power draw consistency.
HighCapacity Direct Shipping Ore Operation
چيلنج: A DSO producer needed extremely highvolume primary crushing (>8k tph) but had limited space available at their rail loadout facility due to existing infrastructure constraints
حل: A compact yet highcapacity gyratory configuration paired with steepangle conveying systems was engineered specifically within tight spatial parameters
نتيجا: The tailored design met all throughput requirements while fitting into only eighty percent of the space originally thought necessary saving significant capital that would have been required for site earthworks modifications
HighCapacity Direct Shipping Ore Operation
چيلنج A DSO producer needed extremely highvolume primary crushing (>8k tph) but had limited space available at their rail loadout facility due existing infrastructure constraints حل A compact yet highcapacity gyratory configuration paired steepangle conveying systems was engineered specifically within tight spatial parameters نتيجا The tailored design met all throughput requirements while fitting into only eighty percent space originally thought necessary saving significant capital would have been required site earthworks modifications
HighCapacity Direct Shipping Ore Operation
چيلنج A DSO producer needed extremely highvolume primary crushing (>8k tph) but had limited space available at their rail loadout facility due existing infrastructure constraints حل A compact yet highcapacity gyratory configuration paired steepangle conveying systems was engineered specifically within tight spatial parameters نتيجا The tailored design met all throughput requirements while fitting into only eighty percent space originally thought necessary saving significant capital would have been required site earthworks modifications
HighCapacity Direct Shipping Ore Operation
چيلنج A DSO producer needed extremely highvolume primary crushing (>8k tph) but had limited space available at their rail loadout facility due existing infrastructure constraints حل A compact yet highcapacity gyratory configuration paired steepangle conveying systems was engineered specifically within tight spatial parameters نتيجا The tailored design met all throughput requirements while fitting into only eighty percent space originally thought necessary saving significant capital would have been required site earthworks modifications
HighCapacity Direct Shipping Ore Operation
چيلنج A DSO producer needed extremely highvolume primary crushing (>8k tph) but had limited space available at their rail loadout facility due existing infrastructure constraints حل A compact yet highcapacity gyratory configuration paired steepangle conveying systems was engineered specifically within tight spatial parameters نتيجا The tailored design met all throughput requirements while fitting into only eighty percent space originally thought necessary saving significant capital would have been required site earthworks modifications
HighCapacity Direct Shipping Ore Operation
چيلنج A DSO producer needed extremely highvolume primary crushing (>8k tph) but had limited space available at their rail loadout facility due existing infrastructure constraints حل A compact yet highcapacity gyratory configuration paired steepangle conveying systems was engineered specifically within tight spatial parameters نتيجا The tailored design met all throughput requirements while fitting into only eighty percent space originally thought necessary saving significant capital would have been required site earthworks modifications
HighCapacity Direct Shipping Ore Operation
