Iron Ore Crushing Plant Oem Factory Samples
1. HAPJE NGA PIKA E DIKIMIT
Managing an iron ore crushing plant presents distinct challenges that directly impact your bottom line. A po luftoni me:
Koha e tepruar joproduktive: Unplanned stoppages for liner changes, blockages, or mechanical failures, kushton mijëra në orë në prodhim të humbur.
Shpenzimet e paplanifikuara të mirëmbajtjes: Premature wear on crusher components from abrasive hematite or magnetite, duke çuar në të shpeshta, costly part replacements and labor.
Produkt i paqëndrueshëm & Madhësia e produktit: Fluctuations in feed size or hardness causing bottlenecks, reducing overall plant efficiency and failing to meet precise sinter or pellet feed specifications.
Konsumi i lartë i energjisë: Inefficient crushing chambers and drives that escalate operational costs, especially under continuous, highload operation.
System Integration Headaches: New equipment that fails to interface correctly with existing screening and conveying systems, creating installation delays and operational silos.
Pyetja kryesore për menaxherët e uzinës është: how can you achieve reliable tonnage, predictable maintenance intervals, and optimal costpertonne in your primary crushing stage?
2. PËRMBLEDHJE E PRODUKTIT
Our engineered solution is a Primary Gyratory Crusher Station specifically configured for iron ore processing. This turnkey module is designed as the first critical size reduction stage in a comminution circuit.
Rrjedha e punës operative:
1. Marrja e ushqimit: Runofmine (ROM) iron ore is delivered via haul trucks to a robust dump hopper with grizzly sections to bypass subcrusher fines.
2. Thërrmimi primar: Material is fed into the gyratory crusher, where a mantle gyrates within a concave bowl, applying compressive force to reduce ore to a nominal 150250mm product.
3. !Shkarkimi & Transporti: Crushed ore is discharged onto a heavyduty apron or belt feeder, which regulates flow onto the main plant conveyor for transport to secondary crushing or stockpiling.
Fusha e Aplikimit: Ideale për kapacitet të lartë (5,000 12,000+ tph) iron ore mining operations processing hard and abrasive ores. Suitable for both greenfield installations and retrofit upgrades.
Kufizimet: Not designed as a finished product crusher; requires secondary/tertiary stages for fine crushing. Site requires adequate foundation engineering and feed system compatibility.
3. TIPARET THEMELORE
Patented Concave Profile | Baza Teknike: Optimized crushing chamber geometry | Përfitimi Operacional: Delivers consistent reduction ratio with lower risk of bridging; promotes interparticle crushing for efficiency | Ndikimi i ROI: Të dhënat në terren shfaqen deri në 8% higher throughput for equivalent power draw
Liner Life Enhancement System | Baza Teknike: Integrated liner backing material and automated bolt tensioning | Përfitimi Operacional: Ensures even wear distribution and secure liner retention, maximizing service life | Ndikimi i ROI: Reduces liner changeout frequency by 1525%, lowering parts inventory cost and labor hours
Hidroset & Automation Interface | Baza Teknike: Hydraulic adjustment for crusher setting (CSS) with PLC integration | Përfitimi Operacional: Allows remote adjustment during operation for quick compensation to feed changes; provides realtime condition monitoring | Ndikimi i ROI: Minimizes product spec deviations and enables predictive maintenance, reducing unplanned downtime by up to 30%
HeavyDuty Main Shaft Design | Baza Teknike: Forged alloy steel shaft with precision machining | Përfitimi Operacional: Provides exceptional resistance to bending stress and fatigue under cyclical loading from hard ore bodies | Ndikimi i ROI: Eliminates main shaft failure as a lifecycle risk, protecting against catastrophic repair costs exceeding typical component replacement
Integrated Dust Sealing & Suppression | Baza Teknike: Multistage labyrinth seals paired with optional injection ports | Përfitimi Operacional: Contains abrasive dust particles within the crusher cavity, protecting bearings and lubricants | Ndikimi i ROI: Extends bearing service life by up to 40% and reduces environmental contamination
Sistemi i bashkimit të drejtpërdrejtë të drejtimit | Baza Teknike: Lowspeed synchronous motor coupled directly to the crusher via flexible coupling | Përfitimi Operacional: Eliminates gear train losses and associated maintenance; provides high starting torque for loaded starts | Ndikimi i ROI: Arrin deri në 5% higher energy efficiency compared to traditional Vbelt drives over longterm operation
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi standard i industrisë | Our Primary Gyratory Crusher Solution | Avantazhi i dokumentuar |
| : | : | : | : |
| Disponueshmëria (Koha e planifikuar e ekzekutimit) | 9294% | 9697%| +3% përmirësim |
| Liner Life (Abrasive Iron Ore) | ~6 Months Average| 7.5 8 Months Average| +25% përmirësim |
| Konsumi specifik i energjisë (kWh/t)~0.25 0.32 kWh/t~0.22 0.28 kWh/t~12% improvement |
| Koha mesatare ndërmjet dështimit (Komponentët kritikë)~18 Months~24+ Months~33% improvement |
| Konsistenca e xhiros (± % from target)| ±10%|<±6%|40% greater consistency |
5. SPECIFIKIMET TEKNIKE
Gama e Kapacitetit: I konfigurueshëm nga 5,000 deri në fund 12,000 ton në orë (tph), dependent on feed size and material work index.
Kërkesat për fuqi: Motorët kryesorë të drejtimit nga 450 kW deri në 1 MW+; supplied for [specify voltage/frequency per region].
Specifikimet e materialit: Highchrome alloy concave liners; Manganese steel mantle options; Cast steel mainframe with stressrelief annealing.
Dimensionet fizike (Shembull): Total station footprint ~15m x 10m; Feed opening up to 1,500mm; Discharge setting range 150250mm.
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 30°C deri në +50°C; dust protection rating IP65 on critical drives; suitable for highaltitude operation.
6. Skenarët e APLIKIMIT
LargeScale Open Pit Magnetite Operation
Sfida: Needed to increase primary crushed tonnage by 20% without expanding footprint or truck fleet due to mine plan expansion.Solution: Retrofitted existing primary station with our highcapacity gyratory crusher featuring the optimized concave profile and direct drive system.Rezultatet: Arriti një rritje të qëndrueshme të xhiros prej 22%. Energy consumption per tonne dropped by 9%. The retrofit was completed within an eightweek planned shutdown.
Integrated MinetoPellet Plant
Sfida: Frequent liner wear inconsistencies caused unpredictable maintenance shutdowns and fluctuations in secondary circuit feed size.Solution: Implemented our Primary Gyratory Crusher with the Liner Life Enhancement System and Hydroset automation.Rezultatet: Established predictable liner life of 7 months ±5 days. CSS adjustments via Hydroset maintained product sizing within a tighter band (+/50mm), improving downstream ball mill feed consistency.
7. KONSIDERATA TREGTARE
Our Primary Gyratory Crushers are offered in three core tiers:
1. Detyra standarde
2.HighCapacity Performance
3.UltraHeavy Duty
Optional features include advanced lubrication filtration systems,
automated wear part monitoring sensors,
and modular walkway assemblies for safer maintenance.
We provide comprehensive service packages:
Platinum Support
Gold Support
Basic OnCall Support
Financing options include capital purchase,
operational lease agreements,
and throughputbased contract models structured over multiyear terms.
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