Stone Quarry Crushing Plant ODM Manufacturer Catalog
Targeted Product Overview: Stationary Stone Quarry Crushing Plant
1. PAINPOINT driven اوپننگ
Managing a stone quarry crushing operation presents persistent challenges that directly impact your bottom line. ڇا توهان تجربو ڪري رهيا آهيو:
اعلي آپريشنل Downtime: بار بار مشيني ناڪامي, ڊگھي سار سنڀال ونڊوز, and unscheduled stops for clearing blockages or replacing worn components.
نامناسب فائنل پراڊڪٽ گريڊيشن: Variability in aggregate size distribution, پراڊڪٽ رد ڪرڻ جي ڪري, ڇڪڻ واري چڪر, and difficulty meeting strict project specifications.
Excessive Energy and Wear Costs: Crushers and conveyors operating at nonoptimal levels consume more power. لينر تي وقت کان اڳ پائڻ, جبل, and screens drives up your costperton metric.
LaborIntensive Material Handling: دستي ترتيب ڏيڻ تي انحصار, frequent loader intervention to clear hoppers, and safety risks associated with direct material interaction.
اسڪاليبلٽي حدون: Inflexible plant layouts that cannot be easily adjusted for changes in feed material hardness or shifts in market demand for different aggregate sizes.
These issues translate to quantifiable losses: unplanned downtime can cost thousands per hour in lost production and idle labor. A stationary stone quarry crushing plant engineered to address these specific pain points is not just an equipment purchase; it is a strategic investment in operational predictability.
2. پيداوار جو جائزو
Our stationary stone quarry crushing plant is a complete, hardwired processing system designed for highvolume primary, ثانوي, ۽ ڌماڪيدار پٿر جي ثانوي گھٽتائي مخصوص مجموعي سائزن ۾. Engineered for permanent installation with a lifespan measured in decades, it provides the backbone of continuous quarry output.
آپريشنل ڪم فلو:
1. پرائمري ڊمپنگ & پري اسڪريننگ: رنوفڪريري (ROQ) material is dumped into a largecapacity receiving hopper, often with a grizzly feeder to bypass subsize material directly to the primary product conveyor.
2. پرائمري سائيز جي گھٽتائي: هڪ مضبوط پرائمري کولہو (typically a jaw or gyratory crusher) performs the initial breakdown of large boulders into manageable fragments.
3. Material Distribution & ثانوي / ٽيٽيري ڪرشنگ: Conveyors transport material to subsequent crushing stages (مخروط يا اثر crushers) وڌيڪ اصلاح لاء. An integrated screening deck sorts material by size.
4. ترتيب ڏيڻ & ذخيرو ڪرڻ: Correctly sized aggregates are routed via conveyor networks to designated stockpiles. oversize مواد recirculated آهي (بند سرڪٽ ڊيزائن) for further crushing.
ايپليڪيشن جو دائرو & حدون:
دائرو: Ideal for hightonnage granite, چونا پٿر, بيسالٽ, پٿر, and other abrasive mineral quarries. Suited for operations requiring consistent output of construction aggregates (روڊ جو بنياد, ڪنڪريٽ جو پٿر, اسفالٽ چپس) ۽ riprap.
حدون: Not mobile or relocatable without significant disassembly. Initial capital outlay and site civil works (بنياد, electrical substation) are substantial. Optimal efficiency requires consistent feed of blasted material; significant clay or highmoisture content may necessitate preprocessing.
3. بنيادي خاصيتون
ذھني ڪنٽرول سسٽم | ٽيڪنيڪل بنياد: PLCbased automation with load and level sensors | آپريشنل فائدا: Monitors crusher load in realtime to regulate feeder speed, preventing chokefeeding or running empty | ROI اثر: تائين 15% reduction in energy consumption and minimized wear from optimal operation cycles.
ماڊل پلانٽ ڊيزائن | ٽيڪنيڪل بنياد: Preengineered structural steel modules with standardized interfaces | آپريشنل فائدا: Allows for phased installation, future expansion (adding a tertiary circuit), or reconfiguration of flow | ROI اثر: Reduces initial construction time by up to 30% and protects longterm investment against changing market needs.
HeavyDuty Wear Component Design | ٽيڪنيڪل بنياد: Highchrome martensitic steel alloys and optimized cavity geometries | آپريشنل فائدا: Significantly extends service life of liners, ڪپڙا, مقدر, and screen meshes under abrasive conditions | ROI اثر: لباس جي حصن جي قيمت گھٽائي ٿو سراسري طور تي 2035%, reducing part change frequency and associated labor.
Integrated Dust Suppression System | ٽيڪنيڪل بنياد: اسٽريٽجڪ طور تي رکيل اسپري نوزز سولينائيڊ والوز سان ڪنويئر آپريشن سان ڳنڍيل آهن | آپريشنل فائدا: Actively controls dust at transfer points and crusher exits without oversaturating material | ROI اثر: Ensures compliance with environmental regulations avoiding fines/ shutdowns; improves site visibility and worker health.
مرڪزي گريسنگ & لوڻ جو نظام | ٽيڪنيڪل بنياد: Automated singlepoint lubrication lines servicing key bearing points across the plant | آپريشنل فائدا: Ensures critical components receive correct lubrication on schedule without manual intervention | ROI اثر: تباهي واري بيئرنگ ناڪامي کي روڪي ٿو; reduces scheduled maintenance time by hundreds of manhours annually.
HighCapacity Surge & Buffer Zones | ٽيڪنيڪل بنياد: Oversized hoppers and strategically placed stockpile conveyors between crushing stages | آپريشنل فائدا: Decouples production stages; if one unit stops briefly upstream/downstream processes can continue temporarily using buffered material| ROI اثر: ٻوٽن جي مجموعي دستيابي کي وڌائي ٿو (اپ ٽائم) by mitigating cascading stoppages.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري معيار | Our Stationary Crushing Plant Solution | دستاويزي فائدو |
| : | : | : | : |
| مجموعي طور تي پلانٽ جي دستيابي (اپٽائم) | 8588% في چوٿون >90% في چوٿون +35 سيڪڙو پوائنٽون |
| توانائي جو استعمال في ٽين پروسيس ٿيل| Varies widely by rock type Up to 18% reduction via system optimization Proven through field performance audits |
| Wear Life of Primary Crusher Liners| abrasive گرينائيٽ فيڊ جي بنياد تي 550650 ڪم جا ڪلاڪ 750+ ڪم جا ڪلاڪ +20% سڌارو |
| ناڪامي جي وچ ۾ وچولي وقت (ايم بي ايف) Drives/Conveyors| ~ 1,200 ڪلاڪ >1,800 ڪلاڪ +50% سڌارو |
| سيٽ اپ ڪريو & ڪميشن جي ٽائيم لائن (گرين فيلڊ)| 46 months from delivery 34 months from delivery ~25% faster due to modular design |
5. ٽيڪنيڪل وضاحتون
ڊيزائن جي گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 300 ختم ڪرڻ 1,500 ميٽرڪ ٽين في ڪلاڪ (ٽي پي ايڇ), depending on model selection and rock characteristics.
بجلي جي گهرج: Primary crusher motor typically ranges from 150kW to 400kW+. Total installed plant power can range from 800kW to over 2MW for large complexes. Requires dedicated highvoltage substation connection.
مواد جي وضاحت: Constructed from heavyduty structural steel (S355JR گريڊ گھٽ ۾ گھٽ). Wear surfaces utilize AR400 steel plate liners. Crusher components use proprietary highgrade alloys.
جسماني طول و عرض & بنياد: A complete plant footprint can range from approximately 50m x 40m for a compact setup to over 150m x 100m for multistage circuits with extensive conveying. Requires engineered concrete foundations with embedded anchor bolts.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل. Dust suppression systems are rated for operation up to 80% نسبتي نمي. Electrical enclosures meet IP65 rating for dust/water ingress protection.
6. درخواست جا منظر
Large Granite Quarry Supplying State Highway Project
چيلنج: Needed guaranteed production of over 1 million tons of precisely graded aggregates within an18month window using highly abrasive granite feed.
حل: Implementation of a threestage stationary crushing plant featuring a primary jaw crusher two secondary cone crushers in paralleland two tertiary cone crushers allin closed circuitwith multideck screens
نتيجا: Achieved sustained outputof950 TPH.Product gradation consistency met DOT specificationswith99pass rateeliminating reprocessingPlant availability averaged92over the project duration
Limestone Quarry Expanding Product Portfolio
چيلنج: An existing quarry producing only base material soughtto capture highervalue marketsfor concreteand asphalt chipswithout disrupting current production
حل: Integrationofan addon tertiarycrushingand precision screening moduleinto the existing stationaryplant layoutusingthe modular design philosophy
نتيجا: Enabled simultaneous productionofthree new spec productsincreased overall revenueper tonby40The expansionwas completedduringa planned12day shutdownwith minimal impacton base material output
7.تجارتي خيالات
Our stationary stone quarry crushing plants are offered under three primary tiers:
1.معياري تشڪيل جو درجو: Includes corecrushing screeningand conveying equipmentwith basic automationfor capacity rangesof300600 TPHPriced asa turnkey solutionincludingfoundation drawingsand commissioning support
2.اعلي دستيابي درجي: Builds upon the standard tierwith premiumwear componentsduplicate critical drivesautomated lubricationand advanced predictive maintenance sensorsIncludes extended warranty coverage
3.CustomEngineered Tier: Forcapacities exceeding800 TPHor complexmaterial characteristicsInvolvesfull CFDanalysisofmaterial flowcustom structural engineeringand fully integratedplantwide process control systems(اسڪاڊا)
Optional features includeonboard weighing systemsmetal detectionradial stacker conveyorsfor stockpilingandsound attenuation enclosures
Service packagesare availablefrom basic technical supportto comprehensive annual maintenance contractsincluding parts kitsand scheduledinspectionsby factorytrained engineersFinancing optionsincludingoperational leasecapital leaseand project financingcan be structuredover termsalignedwith your cash flow projections
8.FAQ
ق:What factors determine whether we needa twostageor threestagecrushing circuit?
اي:The decisionis based primarilyon your required final product sizesfeed size(F80)and the reduction ratio neededA threestagecircuitis necessaryfor producinga wide rangeof productsincludingfine aggregatesor whenhigh cubicityis requiredField datashowsmostgranitequarriesrequirethree stageswhile some limestoneoperationscan operateefficientlywith two
QHow does this system integratewith our existingprimary blastingand loading operations?
اي:The stationaryplant designstarts atthe receiving hopperWe conducta full analysisofyour haul truck fleetto dimensionthe hopperfor efficient dumpingThe control systemcan be interfacedwith your weighbridgefor total production trackingIntegrationis standardpractice
QWhat isthe typical implementationtimelinefrom orderto full operation?
AFora Standard Tierplantlead timeis typically68 monthsfrom order approvalThis includesengineeringmanufacturingshippingand onsite erectionCommissioningand operator trainingrequirean additional24 weeksdependingon complexitySite preparation(foundationsutilities)must proceedin parallel
QAre spare parts readily availablegiven our remote location?
AWe maintaina global networkof certified parts depotsCritical wear part profilesare stockedbasedonyour specific rock analysisFurthermoreour maintenance contractscan include strategic onsite parts inventoryto minimizeany potentialdowntime
QCan this plantbe automatedto runwith minimal operator intervention?
AYeswhile initial feedingmay requireloader operationthe entirecrushingscreeningand conveying processcan be automatedfroma central control roomThe systemmanages feeder ratescrusher settingsconveyor sequencingbasedon preset parametersrequiringonly monitoring
