Stone Quarry Crushing Plant Producer Procurement
1. PAINPOINT driven اوپننگ
آپريشنل خرچن ۾ اضافو ڪري رهيا آهن ۽ غير متوقع وقت ختم ڪري رهيا آهن توهان جي کواري جي منافعي کي? پٿر جي کوٽائي ڪرڻ واري پلانٽ کي منظم ڪرڻ مختلف چئلينج پيش ڪري ٿو جيڪي سڌو سنئون توهان جي هيٺئين لائن تي اثر انداز ڪن ٿا. عام درد جون پوائنٽون شامل آهن:
سار سنڀال لاءِ اضافي وقت: بار بار لائنر تبديليون, برداشت جي ناڪامي, ۽ غير متوقع ڀڃڪڙي پيداوار کي روڪيو. انڊسٽري ڊيٽا اشارو ڪري ٿو ته غير منصوبابندي ڪيل وقت ختم ٿي سگھي ٿو $10,000 في ڪلاڪ گم ٿيل پيداوار ۽ محنت ۾.
متضاد پيداوار جي درجه بندي: فيڊ جي مواد يا کولہو جي ڪارڪردگي ۾ ڦيرڦار آف اسپيڪ مجموعي جي ڪري ٿي, پيداوار جي رد ٿيڻ جي نتيجي ۾, ٻيهر ڪرڻ جي قيمت, ۽ غير مطمئن گراهڪ.
اعلي توانائي واپرائڻ: غير موثر ڪرشنگ چيمبر ۽ ڊرائيو تمام گهڻي طاقت استعمال ڪن ٿا, making energy one of the largest variable costs in your processing circuit.
تيز لباس واري حصي جي تباهي: Abrasive stone varieties cause accelerated wear on liners, هٿيار, ۽ جبڙا, leading to high consumable costs and frequent production pauses.
محدود لچڪدار & اسڪاليبلٽي: Inflexible plants struggle to adapt to changing market demands for different aggregate sizes or increased throughput.
Is your current solution equipped to minimize these operational risks? The right primary crushing station is not just a purchase; it's a strategic investment in plantwide stability and efficiency.
2. پيداوار جو جائزو
The cornerstone of any efficient operation is a robust primary jaw crusher station. Engineered for the initial reduction of blasted quarry rock (typically from 600900mm down to 150250mm), this equipment forms the critical first stage in your size reduction circuit.
آپريشنل ڪم فلو:
1. کاڌ خوراڪ: Dump trucks or wheel loaders deposit shot rock into a heavyduty vibrating grizzly feeder (وي جي ايف ايف وي جي ايف).
2. پري اسڪريننگ & بائي پاس: The VGF removes natural fines and sub150mm material, directing it to a bypass conveyor to reduce unnecessary crusher load and wear.
3. پرائمري ڪرشنگ: Oversize material is conveyed into the jaw crusher, جتي هڪ مقرر جبو ۽ هلندڙ جبو پٿر کي ٽوڙڻ لاءِ زبردست دٻاءُ واري قوت جو استعمال ڪن ٿا.
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: سخت پٿر جي کوٽائي لاء مثالي (گرينائيٽ, بيسالٽ, پٿر جو پٿر) and abrasive applications. Suited for stationary primary crushing stations.
حدون: حتمي پراڊڪٽ جي شڪل ڏيڻ يا الٽرافائن ڪرشنگ لاءِ ٺهيل ناهي. Requires competent feed material; sticky or highclay content feed can cause chamber packing without proper prescreening.
3. بنيادي خاصيتون
ڊيپ ڪرشنگ چيمبر & جارحتي نپ زاويه | ٽيڪنيڪل بنياد: آپٽمائزڊ ڪينيميٽيڪس ڊيزائن | آپريشنل فائدا: Enables higher throughput capacity and effective breaking of larger feed blocks | ROI اثر: Increases processed tons per hour (ٽي پي ايڇ), improving asset utilization
HeavyDuty ٺهيل اسٽيل فريم | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي)optimized construction | آپريشنل فائدا: ناقابل برداشت مواد مان جھٽڪو لوڊ ڪرڻ جي خلاف غير معمولي استحڪام فراهم ڪري ٿو | ROI اثر: تباهي واري فريم جي ناڪامي جي خطري کي گھٽائي ٿو, آپريشنل زندگي کي اڳتي وڌائڻ 20 سال
هائيڊولڪ ايڊجسٽمينٽ & صاف ڪرڻ وارو نظام | ٽيڪنيڪل بنياد: ٽوگل ٽينشن ۽ چيمبر صاف ڪرڻ لاءِ انٽيگريٽيڊ هائڊروڪ سلنڈر | آپريشنل فائدا: Allows quick CSS adjustment for product size changes and automatic release of tramp iron | ROI اثر: Cuts adjustment time by 70% بمقابله دستي نظام, گھٽ ۾ گھٽ وقت گھٽائڻ
Bolted Bearing Cartridge Design | ٽيڪنيڪل بنياد: ماڊلر, preassembled bearing housings | آپريشنل فائدا: Enables faster replacement of pitman bearings without machining onsite | ROI اثر: Reduces critical bearing service time from days to hours, significantly boosting availability
QuarryGrade Spherical رولر بيئرنگ | ٽيڪنيڪل بنياد: Oversized bearings with L10 life calculations exceeding 50,000 ڪلاڪ | آپريشنل فائدا: Handles high radial and axial loads with superior reliability | ROI اثر: Lowers total cost of ownership by extending service intervals and preventing unplanned stoppages
Replaceable Liners with Multiple Profiles | ٽيڪنيڪل بنياد: High manganese steel alloys with optional chrome or ceramic additives | آپريشنل فائدا: Offers profile choices (مثال, ناريل, اڌ) to match rock abrasiveness and desired output shape | ROI اثر: Optimizes liner lifetocost ratio; فيلڊ ڊيٽا تائين ڏيکاري ٿو 30% longer life in abrasive granite
انٽيگريڊ موٽر بيس & ڊرائيو گارڊز | Technical Basis Unified baseplate design with safetycompliant guarding| Operational Benefit Simplifies installation alignment and ensures operator safety during routine inspections| ROI Impact Reduces installation labor costs by approximately 15% and mitigates safety incident risk
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | اسان جي جبڑے کولہو حل | فائدو (% سڌارو) |
|||||
| مشيني دستيابي | 9092% | 9496% | +4% اپ ٽائم |
| لائنر زندگي (ابراھيندڙ گرينائيٽ)| 120,000 150,000 ٽين | 180,000 200,000 ٽين | +30% عمر |
| توانائي جو واھپو | بيس لائين | اصلاح ٿيل چيمبر جاميٽري & ڊرائيو |8% kWh في ٽون |
| بيئرنگ مٽائڻ جو وقت | 2436 ڪلاڪ | 812 ڪلاڪ |67% service duration |
| ذريعي جي گنجائش | Baseline TPH Higher stroke & speed capability +15% TPH in comparable duty |
5. ٽيڪنيڪل وضاحتون
ماڊل رينج جي گنجائش: 300 1,800 MT/H (varies by feed material density)
فيڊ اوپننگ رينج: 900mm x 600mm up to 1,500mm x 1,200mm
بجلي جي گهرج: مکيه کولہو موٽر مان 75 kW تائين 300 ڪلواٽ (400V/50Hz يا حسب ضرورت). Complete station includes feeder & conveyor ڊرائيو.
مواد جي وضاحت: Main frame – S355J2 steel; Liners – Mn18Cr2 / Mn22Cr2; Shaft – forged42CrMo4 steel.
جسماني طول و عرض (اسٽيشن): Typical footprint ranges from ~15m L x ~6m W x ~7m H.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل. Dust sealing standard; اختياري حرارتي پيڪيجز موجود آهن.
6. درخواست جا منظر
گرينائيٽ ڪواري توسيع پروجيڪٽ
Challenge A granite quarry needed to increase primary circuit throughput by25%to feed anew secondary cone crusher line without expanding their blasting schedule
Solution Installation ofa highcapacity jaw crusher station with an aggressive nip angle anda deeper chamber tomaximize tonnage from existing feed size
Results Achieveda28%increasein primary throughput(measured intons per blast pile) andreduced the average product size P80by15%, improving secondary cone crusher efficiency
Transitioningto More Abrasive Feed Material
Challenge A limestone quarry facing depletion needed tousea new pitwith significantly more chertand quartz inclusions leading tounacceptable wear rates ontheir existing primary crusher
Solution Retrofitteda new jaw crusher featuring bolted bearing cartridges foreasier maintenanceand installed optional hybrid ceramic/manganese liners inthe most critical wear zones
Results Extended liner change intervals from6weeks backto the original8week cycle despite more abrasive feed reducing annual liner costby22%and maintaining availability
7.تجارتي خيالات
Equipment pricing is tiered based on size capacity:
ٽائر 1(300600ٽي پي ايڇ): Foundational modelsfor smallto midsize quarries
ٽائر 2(6001200ٽي پي ايڇ): Highperformance modelswith advanced hydraulicsand telemetry standard
ٽائر 3(12001800ٽي پي ايڇ): Heavyduty stationsfor largescale mining operations including integrated automation interfaces
اختياري خاصيتون:
Advanced wear monitoring systems Remote vibration sensing packages Automated grease lubrication systems Walkin modules forenclosed maintenance
سروس پيڪيجز:
Level1– Parts& حمايت(standard warranty)
Level2– Scheduled Inspections& حالتن جي نگراني(includes annual health check)
Level3– Full Maintenance Agreement(covers planned parts laborand24/7 emergency support)
Financing Options Available through partner institutions including operating lease capital leaseor projectbased financing typically structured over37years
8.FAQ
Q Can this jaw crusher station integrate with our existing PLC control system?
A Yes most models feature standardized communication protocols(Modbus Profibus) allowing integration into existing plant SCADA systems formonitoring key parameters like power drawand CSS
Q What isthe expected impact onour overall plant energy consumption?
A Field data shows that due toefficient drive designand optimized kinematics our solution typically reduces energy useper tonof crushed material by510% depending onthe rock hardness This directly lowers operating costs
Q ڇا لباس جا حصا عالمي سطح تي آساني سان دستياب آهن?
A We maintain regional inventory hubs onthree continents ensuring critical wear parts like linersare available within48hours formost locations minimizing potential downtime
Q What arethe commercial terms formajor spare parts?
A We offer guaranteed pricing contracts forwear part kits which lock inprices fora defined period(usually1224months) providing predictable budgetingforyour maintenance planning
Q How long doesinstallation typically takeand what site preparation isrequired?
A Fora complete station installation requires approximately1014days with our supervised erection team Site preparation requires level compacted ground anda concrete foundation accordingtosupplied engineering drawings delivered prior tomobilization
