Stone Crusher Plant Factories Procurement
1. PAINPOINT driven اوپننگ
آپريشنل خرچن کي وڌائي رهيا آهن ۽ غير متوقع دير سان توهان جي مجموعي پيداوار جي مارجن کي ختم ڪري رهيا آهن? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, the core challenges in primary crushing often stem from the initial reduction stage. Inefficient or unreliable primary crusher performance creates cascading bottlenecks throughout your entire processing circuit.
عام آپريشنل چئلينج شامل آهن:
سار سنڀال لاء اعلي Downtime: Frequent liner changes and unplanned stops for jam clearing can consume over 15% of available production time annually.
نامناسب کاڌو سنڀالڻ: Fluctuating feed size, نمي, and hardness lead to chokefeeding, wear imbalances, and suboptimal throughput.
اضافي توانائي واپرائڻ: An inefficient crushing chamber design or misapplied technology can increase power costs by 2030% per ton of material processed.
اعلي لباس حصو خرچ: Rapid abrasion of jaws, ڪپڙا, and concaves in abrasive formations results in unsustainable consumables expenditure.
محدود جوڙجڪ لچڪدار: Fixed plants struggle to adapt to changing deposit profiles or new project specifications, locking you into a single operational mode.
Is your primary crushing station a source of constant adjustment and cost, or a reliable foundation for your plant’s profitability?
2. پيداوار جو جائزو: Primary Jaw Crusher Station
A Primary Jaw Crusher Station is a fixed or modular assembly designed for the first stage of size reduction in hard rock quarries, کان کني جا عمل, ۽ وڏي پيماني تي تعميراتي منصوبا. Its function is to accept runofmine (روم) material directly from the quarry face and reduce it to a manageable size for secondary crushing and conveying.
آپريشنل ڪم فلو:
1. کاڌ خوراڪ: ڊمپ ٽرڪون يا لوڊ ڪندڙ جمع وڏي (1.5m تائين) ROM material into a rugged vibrating grizzly feeder (وي جي ايف ايف وي جي ايف).
2. پري اسڪريننگ & بائي پاس: VGF جزا جدا ڪري ٿو (< سي ايس ايس) to bypass the crusher, reducing wear and improving overall efficiency.
3. پرائمري ڪرشنگ: Oversize material is directed into the jaw crusher’s cavity, where a reciprocating jaw exerts immense compressive force against a fixed jaw, breaking rock along its natural fracture lines.
4. خارج ٿيڻ & پهچائڻ: Crushed product is discharged onto a main conveyor at a controlled rate for transport to the next stage.
ايپليڪيشن جو دائرو & حدون:
دائرو: Ideal for hightonnage processing of hard, گرينائيٽ وانگر ٻرندڙ مواد, بيسالٽ, ۽ لوهه. Suited for stationary plants with longlife quarries.
حدون: نرم لاء مناسب ناهي, nonabrasive rock or highly laminated/cleaved material where impact crushing may be more efficient. Requires substantial foundational support and is less mobile than some alternatives.
3. بنيادي خاصيتون
ڊيپ ڪرشنگ چيمبر & جارحتي نپ زاويه | ٽيڪنيڪل بنياد: Optimized kinematics for increased compressive force | آپريشنل فائدا: Handles larger feed sizes with fewer bridging incidents; produces a consistent, wellgraded output on the first pass | ROI اثر: Reduces need for prebreaking or secondary hammering; lowers costperton in the primary stage.
HeavyDuty ٺهيل اسٽيل فريم | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي)designed stress distribution | آپريشنل فائدا: Provides unwavering stability under peak loads, فريم جي ٿڪ کي گھٽائڻ ۽ ترتيب ڏيڻ جي مسئلن تي 20+ سال جي خدمت زندگي | ROI اثر: قيمتي ساخت جي مرمت کي ختم ڪري ٿو; protects major capital investment.
هائيڊولڪ ايڊجسٽمينٽ & صاف ڪرڻ وارو نظام | ٽيڪنيڪل بنياد: انٽيگريٽيڊ ڊبليڪٽنگ هائيڊولڪ سلنڈر | آپريشنل فائدا: آپريٽرز کي اجازت ڏئي ٿي بند ٿيل سيٽنگ کي ترتيب ڏيڻ (سي ايس ايس) remotely for product size changes and safely clear blockages in minutes without manual intervention | ROI اثر: Cuts nonproductive downtime by up to 80% during routine adjustments and stall recovery.
BoltOn Wear Liners & Modular Cheek Plates | ٽيڪنيڪل بنياد: Highstrength alloy steel castings with reversible design | آپريشنل فائدا: Enables fast replacement with standard tools; extends service intervals through multiple rotation cycles | ROI اثر: Reduces liner changeout time by over 50%; lowers inventory costs through part commonality.
مرڪزي خودڪار گريسنگ سسٽم | ٽيڪنيڪل بنياد: Programmable lubrication pump with feed lines to all critical bearings | آپريشنل فائدا: Ensures optimal bearing health with precise grease volume control, independent of operator routine | ROI اثر: Prevents premature bearing failure—a leading cause of major crusher repair—extending component life by an average of 40%.
ٽوگل پليٽ حفاظتي نظام | ٽيڪنيڪل بنياد: Mechanically sacrificial cast iron toggle plate | آپريشنل فائدا: مشيني فيوز طور ڪم ڪري ٿو; fractures under uncrushable overload (مثال, ڌاتو ڌاتو), protecting the crusher from catastrophic damage | ROI اثر: Avoids weeks of downtime and sixfigure repair bills associated with frame or shaft damage.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | پرائمري جبڑے کولہو حل | فائدو (% سڌارو) |
| : | : | : | : |
| دستيابي (اپٽائم) | ~8588% due to maintenance & جام| >92% with hydraulic adjustment & صاف ڪرڻ| +57% وڌيڪ پيداوار ڪلاڪ |
| زندگيءَ جو لباس (ابراھيندڙ پٿر) | 120,000 150,000 ٽين في سيٽ| 180,000 220,000 ٽين في سيٽ| +40% ڊگهي خدمت وقفي |
| توانائي جي ڪارڪردگي (kWh/ٽن)~| وڏي پيماني تي مختلف آهي; baseline = X kWh/ton~| Field data shows X15% kWh/ton~| تائين 15% lower power consumption |
| ذريعي جي گنجائش (tph)~| Rated at ideal conditions~| Sustained throughput at rated capacity in realworld feed conditions~| +1012% higher effective yield |
_Based on comparative field studies in granite quarries._~
_~Specific values depend on model selection and material characteristics._
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: 500 1,600 ميٽرڪ ٽين في ڪلاڪ (MTPH), ماڊل ۽ فيڊ جي درجه بندي تي منحصر آهي.
فيڊ کولڻ: 1,000mm x 650mm کان 1,500mm x 1,200mm تائين.
بجلي جي گهرج: مکيه کولہو موٽر مان 90 kW تائين 300 ڪلواٽ. Total station power including VGF and conveyors typically ranges from 200 kW کان 450 ڪلواٽ.
مواد جي وضاحت: Main frame constructed from hightensile strength steel plate (Min. طاقت پيدا ڪرڻ 355 ايم پي اي). Wear parts available in several manganese steel grades (14%,18%,22%) for optimal cost/performance matching.
جسماني طول و عرض (عام اسٽيشن): ڊگھائي ~ 25m; ويڪر ~ 8m; اوچائي ~ 7m (ڊسچارج کنويئر کان سواء).
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل. مٽي کي دٻائڻ وارو نظام تيار آهي. Noise emissions compliant with <85 ڊي بي(اي) آپريٽر اسٽيشنن تي.
6. درخواست جا منظر
گرينائيٽ ڪواري جي توسيع
چيلنج: هڪ وڏي گرينائيٽ کوٽائي جي ضرورت آهي بنيادي سرڪٽ throughput کي وڌائڻ لاء 25% without expanding its footprint or changing feed size from new blasting patterns.
حل: Implementation of a highcapacity singletoggle jaw crusher station with an optimized grizzly feeder section to improve feed distribution.
نتيجا: جي هڪ مسلسل throughput اضافو حاصل ڪيو 28%. Wear part consumption per million tons decreased by an estimated18%, meeting expansion goals within the existing layout.
لوھ جي لوھ پروسيسنگ پلانٽ Retrofit
چيلنج: Chronic downtime due to tramp steel causing catastrophic damage in the existing primary crusher,
averaging12 days of lost production annually.
حل:
Retrofit installation featuring an enhanced tramp release system using energyabsorbing hydraulic cylinders
and an automatic reset function.
نتيجا:
Eliminated major damage events.Recovery from uncrushable objects now takes less than
30 minutes.Incidentrelated downtime reduced by over95%.
7.تجارتي خيالات
Equipment pricing tiers are primarily determined by capacity size
۽ حسب ضرورت جي سطح:
• ٽائر I(معياري ڊيوٽي):مسلسل لاء,friable material.Highest cost efficiency
for defined applications.
• ٽائر II(ڳري ڊيوٽي):Our most common selection
for hard rock quarries.Includes standard hydraulic adjustment
and heavier components.Balances performance
with durability
• ٽائر III(Modular/SkidMounted):Designed
for faster installation
or semimobile requirements.Priced accordingly
اختياري خاصيتون:
• Automated wear monitoring systems
• Advanced motor starters(وي ايس ڊي)
• Integrated dust suppression packages
سروس پيڪيجز:
• ڪم ڪرڻ & آپريٽر ٽريننگ
• Planned Maintenance Agreements(with guaranteed parts availability)
• Remote Performance Monitoring Subscription
فنانسنگ جا اختيار:
سرمائيداري خرچ سامان ليزنگ پروگرامن ذريعي ترتيب ڏئي سگهجي ٿو,
longterm rentaltoown agreements,
or project financing partnerships tailored
for largescale infrastructure development
8.FAQ
Q1:
How do I determine if this type is suitable versus gyratory crusher?
اي:Gyratory crushers excel at very high tonnage(>1，500 tph)
in mining.Jaw stations offer lower capital cost，
simpler maintenance，
and better handling
of slabby material，
making them preferred
for most quarry applications up
to ~1，200 tph
Q2:
What infrastructure is required?
اي:A substantial reinforced concrete foundation capable
of supporting dynamic loads，
adequate crane access
for wear part replacement，
and integration points
for raw feed supply
and crushed product conveyors are essential
Q3:
Can it handle wet，sticky material?
اي：While capable，
excessive clay or moisture significantly increases risk
of packing/choking.A robust vibrating grizzly feeder(اسڪيلپر)
is critical，
and alternative primary crushing types may be recommended
Q4：
What is typical installation timeline？
اي：For complete station including foundation，
allow8–14 weeks from delivery depending on site readiness.Modular skid versions can reduce this timeline significantly
Q5：
How are wear parts priced？
اي：Parts are offered under transparent pricing models—either fixedprice per operating hour agreements（cost certainty）or direct purchase.Consumables cost per ton processed should be calculated during application review
