پٿر جي کوٽائي ڪرشنگ پلانٽ ٺيڪيدار ٺاهيندڙ سستا
1. PAINPOINT driven اوپننگ
Are you managing a stone quarry operation where profit margins are consistently pressured by equipment performance? The challenges of primary crushing are often the bottleneck. انهن عام آپريشنل رڪاوٽن تي غور ڪريو:
سار سنڀال لاءِ اضافي وقت: بار بار لائنر تبديليون, اڻڄاتل برداشت جي ناڪامي, and wear part replacement halt your entire production line, گم ٿيل آمدني ۾ في ڪلاڪ هزارين خرچ.
نامناسب فيڊ سائيز & ذريعي: پلنگ, علحدگي, and irregular feed from the quarry face lead to poor crusher cavity fill, ظرفيت کي گھٽائڻ ۽ اڻ برابريءَ سان لباس وڌائڻ.
اعلي آپريشنل خرچ: پروسيس ٿيل مواد جي في ٽين توانائي جو استعمال, coupled with the high and frequent cost of wear parts like mantles, مقدر, ۽ جبڑے جي پليٽ, directly erode profitability.
پيداوار جي معيار ۾ تضاد: Inability to reliably control topsize output or an excessive proportion of flaky material can impact downstream processes and final product marketability.
حفاظت & Accessibility Concerns: Routine inspections and maintenance tasks that are timeconsuming or require personnel to work in hazardous proximity to the equipment.
Is your primary crushing station a source of reliability or a recurring cost center? The right contract manufacturer for your stone quarry crushing plant addresses these issues at the design phase, focusing on total cost of ownership rather than just initial purchase price.
2. پيداوار جو جائزو
This content outlines the critical considerations for a stationary primary jaw crusher station within a complete stone quarry crushing plant. Designed as the first mechanical reduction stage, this system is engineered for high availability and low costperton in hard rock applications like granite, بيسالٽ, ۽ چونا پٿر.
آپريشنل ڪم فلو:
1. کاڌ خوراڪ: Dump trucks or wheel loaders discharge runofquarry (ROQ) material into a rugged vibrating grizzly feeder (وي جي ايف ايف وي جي ايف).
2. پري اسڪريننگ & ڏنڊ هٽائڻ: The VGF scalps out natural fines and subcrushsize material via its grizzly bars, bypassing the crusher to increase efficiency and reduce wear.
3. ابتدائي گھٽتائي: Oversize material is conveyed into the jaw crusher cavity, where compressive force between a fixed and a moving jaw plate fractures the rock.
4. خارج ٿيڻ & پهچائڻ: کرش ٿيل مواد کي ثانوي کرشنگ يا ذخيرو ڪرڻ لاءِ ٽرانسپورٽ لاءِ مکيه پراڊڪٽ کنويئر تي خارج ڪيو ويندو آهي.
ايپليڪيشن جو دائرو & حدون:
دائرو: Hightonnage لاء مثالي, abrasive hard rock quarries requiring a robust primary breaker. Optimal for material with compressive strength up to 400 ايم پي اي.
حدون: چپچپا لاء مناسب ناهي, مٽيريل مواد بغير پروسيسنگ جي. A gyratory crusher may offer superior throughput for capacities exceeding 1,500 tph in certain configurations.
3. بنيادي خاصيتون
HeavyDuty Vibrating Grizzly Feeder (وي جي ايف ايف وي جي ايف) | ٽيڪنيڪل بنياد: Highstrength steel plate construction with boltin AR liners | آپريشنل فائدا: Regulates feed rate to the crusher, پلنگ کي ختم ڪري ٿو, removes fines to prevent crusher packing | ROI اثر: Increases effective crusher capacity by up to 15% and reduces unnecessary wear on crusher components
WedgeBased Jaw Plate Adjustment System | ٽيڪنيڪل بنياد: Mechanically locked wedges replace traditional shim plates | آپريشنل فائدا: محفوظ ڪري ٿو, fast CSS adjustment and jaw plate changes from the crusher’s nondrive side in under two hours | ROI اثر: گھٽ ۾ گھٽ وقت گھٽائي ٿو معمولي ترتيبن لاءِ تقريباً 60%, maximizing productive operating hours
اصلاحي ڪرشنگ چيمبر جاميٽري | ٽيڪنيڪل بنياد: Computermodeled kinematics and nip angle design | آپريشنل فائدا: Promotes deepbed crushing throughout the chamber for consistent particleonparticle breakage | ROI اثر: Produces a more cubical product shape (improving secondary crush efficiency) and extends jaw plate service life by distributing wear more evenly
انٽيگريڊ موٽر بيس & بيلٽ گارڊ | ٽيڪنيڪل بنياد: Unified steel fabrication housing crusher motor(ايس) ۽ ڊرائيو گارڊ | آپريشنل فائدا: Eliminates complex field alignment during installation; محفوظ مهيا ڪري ٿو, integral guarding compliant with site safety standards | ROI اثر: تنصيب جي وقت ۽ قيمت تائين گھٽائي ٿي 30%, ensuring faster commissioning
مرڪزي گريسنگ پوائنٽس & حالت مانيٽرنگ پورٽ | ٽيڪنيڪل بنياد: Lube lines routed to accessible groundlevel stations with ports for vibration/temperature sensors | آپريشنل فائدا: Enables daily lubrication and health checks without operators needing to access elevated platforms near moving parts | ROI اثر: Enhances preventative maintenance adherence, improving bearing life and preventing catastrophic failures
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | اسان جي پٿر جي کوٽائي ڪرشنگ پلانٽ حل | فائدو (% سڌارو) |
| : | : | : | : |
| لائنر جي تبديلي جو وقت | 68 ڪلاڪ (جبلن جي پليٽ) | < 2 ڪلاڪ (جبلن جي پليٽ) | ~70% تيز |
| توانائي جي ڪارڪردگي| 0.85 1.1 kWh/ton پروسيس ٿيل| نشانو: 10% سڌارو |
| کولہو جي دستيابي| ~9294% (مقرر & اڻ شيڊول)| ڊيزائن جو مقصد: >96%| ~ 34٪ واڌارو |
| لباس جو حصو استعمال| ~6070% of theoretical weight used before changeout| Design enables use of >85% of liner mass| ~25% better utilization |
5. ٽيڪنيڪل وضاحتون
ماڊل ريفرنس: STQPrimary1442HD
کولہو جو قسم: HeavyDuty سنگل ٽوگل جبڑے کولہو
فيڊ کولڻ: 1400mm x 1100mm (55" x 42")
وڌ ۾ وڌ فيڊ سائيز: 1000ايم ايم (40") ڪنڊ ڊگھائي
بند طرف سيٽنگ (سي ايس ايس) حد: 150mm 300mm (6" 12")
گنجائش جي حد: 450 850 ميٽرڪ tph (فيڊ جي درجه بندي تي منحصر آهي & سي ايس ايس)
ڊرائيو پاور جي گهرج: 200 ڪلواٽ (275 ايڇ پي), electric motor with softstart compatibility
Total Plant Power Demand (Feeder/Crusher/Conveyors): لڳ ڀڳ. 350 ڪلواٽ
اهم مواد جي وضاحت: مکيه فريم ٺهيل اسٽيل پليٽ; Jaw plates Manganese steel alloy; Shaft جعل سازي مصر اسٽيل; بيرنگ اسپيريل رولر جو قسم.
لڳ ڀڳ پيرن جا نشان (ايل ايڪس ڊبليو): 18m x 8m
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; dustsealed بيرنگ; weather protection covers standard.
6. درخواست جا منظر
گرينائيٽ ڪواري توسيع پروجيڪٽ
چيلنج: An existing granite quarry needed to expand production but was constrained by an aging primary plant causing over 40 hours of unplanned downtime monthly due to reliability issues.
حل: Contract design and supply of a complete new primary stone quarry crushing plant station built around a heavyduty jaw crusher with enhanced accessibility features.
نتيجا: Postinstallation data showed plant availability increased from 88% جي طرف 96%. Unplanned downtime was reduced by over 90%, enabling the site to meet its expanded production target within six months.
Basalt Aggregate Producer Seeking Cost Control
چيلنج: A producer faced volatile profitability due to uncontrollably high energy costs per ton and rapid wear part consumption in their primary stage.
حل: Implementation of an optimized plant design featuring chamber geometry focused on energyefficient breakage and a feeder system that removed more fines prior to crushing.
نتيجا: Field data tracked over one year showed a reduction in specific energy consumption from 0.98 kWh/ton to 0.82 kWh/ton—a direct utility cost saving—and extended average jaw plate life by approximately 22%.
7. تجارتي خيالات
Our approach as your contract manufacturer is based on transparent value engineering:
قيمت جا درجا
1. Standard Plant Package includes core equipment as specified above with basic walkways/platforms.
2.Optimized Plant Package includes additional features such as dust suppression system integration advanced condition monitoring sensor packages automated grease systems (+1015%)
3.Turnkey Project Package includes full civil design support installation supervision commissioning services (+مختلف ٿي)
Optional Features include metal detection systems tramp iron relief automation hydraulic setting adjustment vs manual modular skid designs for faster relocation
سروس پيڪيجز:
• Commissioning Support Onsite training operational readiness review
• Planned Maintenance Contracts Guaranteed parts supply scheduled inspections fixed annual cost models
• Performance Audits Annual review of throughput wear rates efficiency recommendations
Financing Options available through our partners include capital lease operating lease longterm rentaltoown structures tailored typically over 3 7 10year terms
8.FAQ
Q What if my current secondary crushers are not from your company? Is compatibility an issue?
A No Our stone quarry crushing plant is designed as an independent modular station Output specifications including product size distribution are engineered based on your input requirements ensuring seamless interface with any downstream equipment via proper transfer conveyors
Q How does this solution address my high energy costs?
A Energy efficiency is engineered into multiple components including optimized feedercrusher interaction efficient drive motor selection correctly sized gearboxes The overall system design aims minimize bottlenecks that cause motors run underloaded which inefficient Field data shows our optimized plants typically achieve measurable reductions specific energy consumption kWh per ton processed
Q What guarantees do you provide on performance metrics like throughput?
A We provide process performance guarantees based agreedupon feed material characteristics These are detailed commercial terms within contract specifying test methods duration We guarantee mechanical performance structural integrity workmanship standard industryleading warranties major components
Q Can you accommodate limited space on my existing site?
A Yes As contract manufacturer we specialize designing plants fit constrained layouts offering modular configurations vertical arrangements reduce footprint compared traditional horizontal flow designs Detailed layout studies conducted during proposal phase ensure feasibility before commitment made
Q What typical lead time expected from contract signing delivery?
A For standard configured stone quarry crushing plant lead times typically range 6 9 months depending complexity current manufacturing schedule Expedited options may available additional cost Longlead items like castings forgings identified early process
