Stone Crusher Plant Sourcing

Short Description:

1. PAINPOINT DRIVEN OPENING Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the core challenges in primary crushing often stem from equipment not matched to the full scope of material and output demands. Common pain points include: Unscheduled Downtime & High Wear Costs: Abrasive feed…

Send email to us Download as PDF

Product Detail

Product Tags

1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the core challenges in primary crushing often stem from equipment not matched to the full scope of material and output demands. Common pain points include:

Unscheduled Downtime & High Wear Costs: Abrasive feed material rapidly degrades crusher components not engineered for specific abrasion indices, leading to frequent liner changes and associated labor costs, halting your entire processing line.
Inconsistent Throughput & Bottlenecks: Underpowered or incorrectly configured primary crushers create a bottleneck, failing to feed downstream screens and conveyors at an optimal rate, capping your plant’s total potential output.
Excessive Fines Generation & Product Mismanagement: Improper crushing chamber geometry and stroke can produce a higher percentage of undersized material than required, reducing saleable product yield and increasing waste.
High Operational Complexity & Safety Risks: Manual adjustment systems for setting changes or clearing blockages increase exposure time in highrisk areas and require skilled personnel, impacting both safety protocols and operational agility.

Is your primary crushing station a source of reliability, or a recurring cost center? The solution lies in selecting a primary stone crusher plant engineered not just to break rock, but to optimize your entire production chain’s efficiency and profitability.

2. PRODUCT OVERVIEW

A stationary primary stone crusher plant is a permanently installed system designed for the first reduction of runofmine (ROM) material from large quarried rock (typically up to 1.5m in size) down to a conveyable product, usually between 150mm to 300mm. It forms the critical foundation of any aggregate or mining operation.

Operational Workflow:
1. Feed Intake: ROM material is dumped by haul trucks into a heavyduty vibrating grizzly feeder (VGF).
2. PreScreening & ByPass: The VGF separates fines (e.g., soil, small rocks) from the main feed, directing them to a bypass conveyor while scalping oversize material directly into the crusher.
3. Primary Crushing: The core jaw crusher or gyratory crusher applies compressive force via a fixed and moving surface to fracture the rock.
4. Discharge & Conveyance: Crushed material is discharged onto a main product conveyor for transport to secondary crushing or stockpiling stages.

Application Scope: Ideal for hightonnage quarrying of granite, basalt, limestone, and other abrasive aggregates; largescale mining operations; and major infrastructure project support plants.

Key Limitations: Requires significant civil works for foundation; not suitable for portable or skidmounted applications; initial capital investment is higher than mobile solutions but offers superior longterm throughput and wear life in fixed locations.

3. CORE FEATURES

Deep Crushing Chamber & Optimized Kinematics | Technical Basis: Increased nip angle and longer vertical stroke | Operational Benefit: Enables higher capacity per stroke and reduces bridging incidents | ROI Impact: Sustained design throughput with fewer operational interruptions for clearing

HeavyDuty Fabricated Steel Frame | Technical Basis: Finite Element Analysis (FEA) optimized stress distribution | Operational Benefit: Provides exceptional durability against shock loads from uncrushable material | ROI Impact: Minimizes risk of catastrophic frame failure, protecting longterm asset integrity

Hydraulic Adjustment & Clearing System | Technical Basis: Integrated hydraulic rams for CSS adjustment and chamber clearing | Operational Benefit: Allows quick, safe setting changes and reversal to clear blockages without manual intervention | ROI Impact: Reduces downtime for routine adjustments by up to 80% compared to manual shim systems

Stone Crusher Plant Sourcing

HighPerformance Bearing Cartridge | Technical Basis: Spherical roller bearings mounted in a removable cartridge housing | Operational Benefit: Simplifies bearing replacement and ensures precise alignment for extended service life | ROI Impact: Lowers maintenance time from days to hours during major service intervals

QuarryGrade Jaw Dies & Liners | Technical Basis: Manganese steel alloy composition tailored for specific material abrasiveness | Operational Benefit: Maximizes wear life between changeouts under severe crushing conditions | ROI Impact: Directly reduces costperton for wear parts through extended service cycles

Integrated Motor Base & Drive Guards | Technical Basis: Unified baseplate design with full mechanical guarding | Operational Benefit: Simplifies installation alignment and ensures operator safety around drive components | ROI Impact: Reduces installation labor costs and mitigates compliance risks

4. COMPETITIVE ADVANTAGES

5. TECHNICAL SPECIFICATIONS

Model Designation: PJC1200x900
Crusher Type: HeavyDuty Single Toggle Jaw Crusher
Feed Opening: 1200mm x 900mm (47" x 35")
Maximum Feed Size: ~850mm edge length
Closed Side Setting (CSS) Range: 150mm 300mm
Capacity Range (@ given CSS): 450 750 metric tons per hour (MTPH)
Drive Power Requirement: 160 kW / 200 HP electric motor
Total Installed Plant Power: ~250 kW (incl. VGF & conveyors)
Main Frame Construction: Welded steel plate, stressrelieved
Approximate Total Plant Weight: ~85 metric tons (crusher + feeder + structure)
Foundation Requirements: Reinforced concrete as per supplied load drawings
Environmental Operating Range: 20°C to +45°C ambient; dust suppression system compatible.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: An existing quarry needed to double its annual production but was constrained by an aging primary crusher causing excessive downtime (>15%) due to wear part failures and blockages.
Solution: Installation of our PJC1200x900 stationary stone crusher plant with hydraulic adjustment and quarrygrade jaw dies specifically selected for highsilica granite.
Results: Plant availability increased to >96%. Wear part life extended by approximately 28%, contributing directly to a calculated reduction in costperton of crushed material by an estimated $0.15/ton at sustained higher throughput.

LargeScale Limestone Processing for Cement Production

Challenge: A cement plant’s raw material feed required consistent sizing below 250mm but their existing primary impactor was generating excessive fines (40mm), wasting energy on overcrushing.
Solution: Replacement with our configured jawtype primary stone crusher plant featuring deepchamber geometry optimized for limestone compression crushing.
Results: Achieved more controlled fragmentation with the percentage of target product (+40mm/250mm) increasing by over 20%. This reduced load on secondary grinding circuits, leading to an estimated annual energy saving of several hundred thousand kilowatthours.

7. COMMERCIAL CONSIDERATIONS

Our primary stone crusher plants are offered in structured tiers based on capacity:

1. Standard Duty Series (1000 MTPH): For megaquarry applications.

Optional features include:
Automated Setting Regulation based on load feedback
Advanced Condition Monitoring sensors package
Extendedwear component packages

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including scheduled inspections and priority parts supply.

Flexible financing options are available through partners including equipment leasing structures tailored for capital expenditure planning or projectbased financing linked directly to project milestones.

8\. FAQ

Q1\. Is this type of stationary plant compatible with my existing downstream screening/conveying setup?
A1\. Yes provided your downstream equipment can handle the designed output capacity range Our engineering team can review your current layout specifications during presales consultation We provide detailed interface drawings including discharge heights conveyor positions etc ensuring compatibility

Q2\. What is the typical lead time from order placement until commissioning?
A2\. For standard models lead times typically range between six months depending on final configuration This includes manufacturing factory testing disassembly shipping reassembly onsite installation supervision commissioning support Site preparation civil works should be completed prior arrival

Q3\. How does this solution impact my overall site manpower requirements?
A3\. The design emphasizes operational simplicity automation where beneficial Features like remote hydraulic adjustment reduce need personnel perform risky manual tasks However overall staffing levels typically dictated entire processing facility operation not single machine unit Training provided ensure efficient operation maintenance procedures established

Q4\. What are key factors determining total cost ownership beyond initial purchase price?
A4\. Primary factors include wear part consumption rates expressed costperton energy consumption measured kWh/ton scheduled preventive maintenance labor costs potential production losses due unscheduled downtime Our solutions engineered optimize each these variables providing detailed lifecycle cost analysis during selection process

Q5\. Can you supply complete turnkey installation including civil works foundations?
A5\. We specialize supply erection commissioning core crushing equipment itself We work closely network certified local civil engineering contractors who can execute foundation work based our detailed specifications We manage interface coordination ensure seamless project execution

Tags: Stone Crusher Plant Sourcing