Stone Crusher Plant Manufacturer Quote
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, پرائمري ڪرشنگ ۾ بنيادي چئلينج اڪثر ڪري ٽن نازڪ علائقن تي مرڪز آهن:
اڻ شيڊول بند وقت & اعلي سار سنڀال خرچ: بار بار لائنر تبديليون, غير متوقع اجزاء جي ناڪامي, and lengthy repair cycles halt your entire processing line. Every hour of stoppage represents significant lost revenue and spiraling labor costs.
غير مطابقت واري پيداوار & Poor Particle Shape: Fluctuating feed material hardness and size can lead to inconsistent product gradation and suboptimal particle shape. This directly impacts the efficiency of downstream processes and can reduce the market value of your final aggregate.
Rigid Configuration & Scalability Limits: Fixed crushing setups struggle to adapt to changing project demands or ore body characteristics. This inflexibility can force you into premature capital expenditure for a new line or result in chronic underutilization of equipment.
How do you achieve reliable throughput with lower costperton, مسلسل پيداوار جي وضاحت کي يقيني بڻائي, and build flexibility into your capital investment? The solution begins with selecting the right primary crushing foundation.
2. پيداوار جو جائزو: PRIMARY JAW CRUSHER
A Primary Jaw Crusher is a heavyduty, compressiontype crusher designed as the first stage in a mineral processing or aggregate production circuit. It reduces large runofmine (روم) or quarry rock to a manageable size for secondary crushing.
آپريشنل ڪم فلو:
1. کاڌ خوراڪ: Large dump trucks deposit ROM material directly into the vibrating grizzly feeder (وي جي ايف ايف وي جي ايف) ahead of the crusher.
2. پري اسڪريننگ & ڪِرڻ: VGF جزا ختم ڪري ٿو ۽ سبسائيز مواد کي نظرانداز ڪري ٿو, ڪرشنگ چيمبر ۾ صرف وڏي وڏي پٿر کي سڌو ڪرڻ. A reciprocating jaw exerts immense force, breaking rock against a stationary jaw.
3. خارج ٿيڻ & پهچائڻ: Crushed material is discharged at the bottom setting and transported via conveyor to the next stage of processing.
ايپليڪيشن جو دائرو: سخت لاء مثالي, گرينائيٽ وانگر ٻرندڙ مواد, بيسالٽ, and iron ore in quarrying, کان کني, and largescale construction aggregate production.
حدون: چپچپا لاء مناسب ناهي, plastic materials. Output is generally less refined than that of cone crushers, making it specifically a primary reduction unit.
3. بنيادي خاصيتون
HeavyDuty فريم & Welded Structure | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي) بهتر دٻاء جي ورڇ | آپريشنل فائدا: Eliminates stress cracking under maximum load cycles; provides stable alignment for all internal components | ROI اثر: Extends structural life beyond industry norms, reducing risk of catastrophic frame failure and associated replacement costs.
ڊيپ سميٽري ڪرشنگ چيمبر | ٽيڪنيڪل بنياد: Increased nip angle and longer linear crushing stroke | آپريشنل فائدا: Enhances capacity by pulling material deeper into the chamber; promotes better particleonparticle breakage for improved shape | ROI اثر: Higher throughput per cycle lowers energy cost per ton; improved shape increases product value.
هائيڊولڪ ٽوگل ايڊجسٽمينٽ سسٽم | ٽيڪنيڪل بنياد: ڊبليڪٽنگ هائيڊولڪ سلنرز روايتي ميخانياتي ٽوگل پليٽ کي تبديل ڪن ٿا | آپريشنل فائدا: Allows remote adjustment of crusher discharge setting for quick product size changes; provides automatic overload protection by releasing tramp metal | ROI اثر: Minimizes downtime for size adjustments from hours to minutes; prevents damage from uncrushables, قيمتي مرمت کان بچڻ.
Bolted Bearing Cartridges | ٽيڪنيڪل بنياد: Precisionmachined cartridge housings with standardized bearing assemblies | آپريشنل فائدا: Enables faster bearing replacement without machining onsite; ensures perfect shaft alignment every time | ROI اثر: Reduces critical path maintenance downtime by up to 50% compared to traditional sleeved bearings.
Fixed Jaw Die Retention System | ٽيڪنيڪل بنياد: Wedgelock system with mechanical or hydraulic assist | آپريشنل فائدا: Secures jaw dies without backing material (مثال, زنڪ); allows for faster, محفوظ مرڻ واريون تبديليون | ROI اثر: Cuts liner changeout time significantly, improving plant availability and reducing labor hours per maintenance event.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | پرائمري جبڑے کولہو حل | فائدو (% سڌارو) |
| : | : | : | : |
| دستيابي (اپٽائم) | ~ 8590% (مقرر & اڻ شيڊول اسٽاپ) |> 94% (فيلڊ ڊيٽا جي بنياد تي) |> 5% increase in production time |
| لائنر جي تبديلي جو وقت (مقرر جبو) | 812 hours with backing compound| 46 hours with wedge system| ~50% تيز |
| قيمت في ٽون (سخت رگڻ وارو پٿر) | Baseline Reference| دستاويز ٿيل 1218% گهٽتائي| Direct OPEX savings |
| توانائي جي ڪارڪردگي (kW per ton crushed)| ڊيزائن جي لحاظ کان مختلف آهي & condition| Optimized kinematics reduce peak loads| تائين 10% سڌارو |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: 150 1,600 MTPH (کاڌ خوراڪ جي مواد ۽ بند پاسي جي جوڙجڪ تي دارومدار).
فيڊ کولڻ: From 800mm x 500mm up to 2,000mm x 1,500mm.
بجلي جي گهرج: 75 ڪلواٽ 400 kW برقي موٽر ڊرائيو.
مواد جي وضاحت: اعلي طاقت جو ٺهيل اسٽيل فريم; Manganese steel wear liners (14%18% من); Forged alloy steel eccentric shaft.
جسماني طول و عرض (مثالي ماڊل): لڳ ڀڳ. ڊگھائي: 7م, ويڪر: 3م, اوچائي: 3.5م; Weight ranges from ~20t to over 120t.
ماحولياتي آپريٽنگ رينج: 40 ° C کان + 50 ° C تائين وسيع گرمي پد لاء ٺهيل; dustsealed بيرنگ; مٽي دٻائڻ واري نظام جي انضمام لاءِ شرطون.
6. درخواست جا منظر
گرينائيٽ ڪواري جي توسيع
Challenge A major quarry needed to increase primary throughput by 30% without expanding their plant footprint or primary feed infrastructure.
Solution Implementation of a new jaw crusher with a deeper chamber and higher stroke capability allowed for a larger feed size acceptance while optimizing power draw.
نتيجن جي ذريعي وڌايو ويو 33%. Improved particle shape reduced recirculating load in the secondary circuit by an estimated 15%, leading to lower overall wear costs.
لوھ لوھ پروسيسنگ پلانٽ اپ گريڊ
Challenge An aging primary crusher was causing bottlenecking due to excessive maintenance requirements and unplanned failures.
Solution Replacement with a modern jaw crusher featuring hydraulic toggle adjustment and cartridge bearing assemblies.
Results Plant availability at the primary stage improved from 81% جي طرف 95%. Annual maintenance labor hours decreased by an estimated 400 hours due to simplified procedures.
7. تجارتي خيالات
قيمت جا درجا: Equipment pricing is structured around feed opening size/capacity tier:
ٽائر I (1000x800mm): Heavyduty range
ٽائر III (>1500x1200mm): Superheavyduty range
Optional Features/Upgrades: Extended wear package (premium liners), automated lubrication systems integrated condition monitoring sensors variable frequency drive VFD motor starters heavyduty skid base frames
سروس پيڪيجز: Available tiers include Basic Warranty Extended Parts & Labor Warranty Annual Inspection Contracts FullService Maintenance Agreements with guaranteed response times
Financing Options Project financing equipment leasing operating leases available through certified partners typically structured over 3 7 10year terms
8. FAQ
Q What are my options if my feed material varies significantly in hardness?
A Our jaw crushers are equipped with hydraulic overload protection as standard This system automatically releases uncrushable material protecting internal components from damage when encountering occasional extreme hardness
Q How does this equipment integrate with my existing secondary crushing circuit?
A Our engineering team can provide interface analysis We ensure discharge dimensions conveyor heights capacities match your current layout Modifications are typically minimal due standardized discharge heights belt widths
Q What is realistic expected operational lifespan before major overhaul?
A With proper maintenance field data shows major components frames shafts eccentrics reliably exceed 15 years service life Wear parts liners bearings vary based application but predictable schedules provided
Q Are there financing structures that align payments with production output?
A Yes performancebased leasing options are available where payment schedules can be partially indexed verified production tonnage providing flexibility during rampup periods market fluctuations
Q What training provided for our operations maintenance teams?
A We supply comprehensive onsite training covering safe operation routine maintenance procedures troubleshooting guides This includes both classroom instruction handson demonstration during commissioning
