1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Are you managing a sand and gravel operation where inconsistent feed material, thời gian ngừng hoạt động quá mức, and rising operational costs are eroding your margins? The challenges of a traditional fixed plant are welldocumented: inflexible layouts that cannot adapt to changing deposit profiles, lengthy setup times that delay production, and high maintenance costs from component wear due to unprocessed oversize material. How much revenue is lost each season during plant relocation and reassembly? What is the true cost of unscheduled downtime caused by crusher blockages or conveyor failures? How can you improve your yield of spec product from variable pit material without constant manual intervention? The solution lies in moving from a static setup to a purposeengineered, modular system.

2. TỔNG QUAN SẢN PHẨM

The Bespoke Sand & Gravel Mining Assembly Plant is a fully modular, semimobile processing system engineered for the specific demands of aggregate extraction. It is not a single machine but an integrated circuit of preengineered modules that can be rapidly configured onsite. Quy trình hoạt động được sắp xếp hợp lý: (1) Primary feeding and scalping to remove deleterious oversize; (2) Primary crushing and initial sizing; (3) Secondary screening and classification; (4) Tertiary crushing/sanding circuit (nếu được cấu hình); (5) Final sorting and stockpiling. This plant is designed for commercialscale sand and gravel pits, alluvial deposits, and construction aggregate recycling operations. Its primary limitation is its designed maximum feed size and hourly tonnage capacity, which are specified during the engineering phase to match your reserve characteristics.

3. TÍNH NĂNG CỐT LÕI

Thiết kế PlugandPlay mô-đun | Cơ sở kỹ thuật: Trượt, prewired/piped modules with standardized connection interfaces | Lợi ích hoạt động: Enables site relocation in days versus weeks, minimizing nonproductive time between pits | Tác động ROI: Reduces redeployment costs by up to 60% and accelerates revenue generation from new deposits.

Intelligent PreScalping Module | Cơ sở kỹ thuật: Highgrizzly or robust vibrating grid section with bypass chute | Lợi ích hoạt động: Removes +150mm oversize and natural debris before the primary crusher, eliminating a major source of jams and wear | Tác động ROI: Lowers crusher liner replacement costs by an estimated 30% and reduces blockagerelated downtime.

Kiểm soát quy trình tập trung & Đo từ xa | Cơ sở kỹ thuật: SCADAbased control panel with remote monitoring sensors on critical components | Lợi ích hoạt động: Your plant manager can monitor throughput, rút điện, and bearing temperatures from a central location, enabling predictive maintenance | Tác động ROI: Ngăn chặn những sự cố thảm khốc, reduces onsite troubleshooting time, and optimizes power consumption per ton.

Điều chỉnh thủy lực & Tramp Relief Systems | Cơ sở kỹ thuật: Hydrosetstyle crusher adjustment and automatic hydraulic release on jaw crushers | Lợi ích hoạt động: Operators can adjust product sizing or clear a cavity blockage in minutes without manual shimming or downtime | Tác động ROI: Maintains consistent product gradation and improves overall plant availability by approximately 57%.

CorrosionResistant Material Handling | Cơ sở kỹ thuật: Abrasionresistant steel liners in hoppers/chutes and UVstabilized rubber on key conveyor belts | Lợi ích hoạt động: Withstands the abrasive nature of sand/gravel slurry and wet processing environments, extending component life | Tác động ROI: Defers capital replacement cycles for wear parts by 2040%, depending on application.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Tiêu chuẩn ngành (Nhà máy cố định) | Bespoke Assembly Plant Solution | Lợi thế (% sự cải tiến) |
| : | : | : | : |
| Site Deployment Time| 46 tuần cho nền tảng & cuộc họp| 710 days for module interconnection| ~75% faster deployment |
| Plant Relocation Flexibility| Giới hạn; often requires disassembly| Cao; modules are transported intact| Enables followonreserve mining |
| OversizeInduced Downtime| Frequent manual clearing required| Automated bypass & intelligent feed control| Field data shows ~40% reduction |
| Mặc một phần chi phí mỗi tấn| Highly variable based on feed control| Controlled via mandatory prescalping| chứng minh 2535% sự giảm bớt |

5. THÔNG SỐ KỸ THUẬT

Phạm vi công suất: Có thể cấu hình từ 150 ĐẾN 600 tấn mỗi giờ (TPH), tùy thuộc vào việc lựa chọn mô-đun.
Yêu cầu về nguồn điện: Integrated electrical distribution for 400V/50Hz or 480V/60Hz supply. Total connected load ranges from 350kW to 900kW.
Thông số vật liệu: Primary structural steel ST37; highwear areas use Hardox 450 or equivalent AR400 steel; polyurethane screen media options.
Kích thước vật lý: Modules designed for standard road transport. Largest single module typically under 3.5m wide x 18m long.
Phạm vi hoạt động môi trường: Được thiết kế cho nhiệt độ môi trường xung quanh từ 20°C đến +45°C. Hệ thống khử bụi được bao gồm theo tiêu chuẩn. Can be configured with heated/premium insulation packages for extreme climates.

6. KỊCH BẢN ỨNG DỤNG

Aggregate Producer with Multiple Pit Sites | Thử thách: A regional producer faced significant lost time and cost each time their fixed plant needed moving between depleted and new sites, dẫn đến hơn 6 weeks of nonrevenue generating activity per year. | Giải pháp: Implementation of a bespoke modular assembly plant with five core processing modules. | Kết quả: Plant relocation time between permitted sites reduced to an average of 12 ngày. This increased annual operational availability by approximately 8%, directly contributing to higher yearly output without capital expenditure on additional fixed plants.

Cát & Gravel Dredging Operation | Thử thách: Variable feed material from a dredge containing large cobbles and organic debris caused chronic blockages in the primary crusher, requiring daily shutdowns for clearing and increasing maintenance labor by two fulltime equivalents. | Giải pháp: Integration of an aggressive heavyduty prescalping module with a dedicated waste conveyor ahead of the crushing circuit in their bespoke plant design.| Kết quả: Oversizerelated stoppages were reduced by over 90%. The operation reallocated maintenance labor to preventive tasks, achieving a more consistent feed rate and improving overall circuit efficiency by an estimated 15%.

7. CÂN NHẮC THƯƠNG MẠI

Pricing for a Bespoke Sand & Gravel Mining Assembly Plant is tiered based on throughput capacity and circuit complexity:
cấp 1 (150250 TPH): Base configuration focusing on core crushing/screening.
cấp 2 (250450 TPH): Includes enhanced prescreening, sand classification cyclones, or washing systems.
cấp 3 (450600 TPH+): Fully comprehensive circuits with multiple product splits, advanced automation, and water recycling plants.

Các tính năng tùy chọn bao gồm các thiết bị chính di động, magnet systems for metal contamination, noise encapsulation packages, and advanced telemetry data logging.

Service packages range from basic commissioning support to comprehensive annual maintenance contracts with guaranteed parts availability schedules.

Financing options include equipment leasing through partner institutions or milestonebased project financing for complete turnkey installations.

8. Câu hỏi thường gặp

1. How quickly can we modify the plant layout if our deposit characteristics change?
The modular nature allows for reconfiguration within days. Ví dụ, adding a washing screw or rerouting conveyors can be achieved by repositioning skidmounted units rather than cutting/welding structural steel.

2. What level of site preparation is required compared to a traditional fixed plant?
Site preparation is significantly reduced as no extensive concrete foundations are needed beyond simple levelling pads or sleeper arrangements for module stability.

3. Is the control system compatible with our existing fleet management software?
The SCADA system provides standard OPC data outputs that can typically be integrated into broader mine management platforms via established industrial communication protocols.

4. What are the lead times from order to commissioning?
Lead times vary by configuration complexity but are generally shorter than fixed plants due to parallel fabrication of modules—typically ranging from [Industry Standard Lead Time] months upon final design approval.

5. How does the operational cost per ton compare over a fiveyear period?
While initial investment may be comparable to some fixed systems industry testing demonstrates that savings in redeployment costs reduced downtime lower wear part consumption typically result in lower total cost ownership over five years particularly multisite operations

6 . Are these plants suitable regions strict environmental regulations noise dust?
Yes They designed incorporate enclosed conveyors covered screens integrated dust suppression spray systems Optional noise abatement kits available meet specific local decibel limits

7 . What happens one module requires major servicing?
The affected module isolated bypassed if possible allowing rest circuit continue operating limited capacity Individual skids transported offsite repair minimizing disruption overall production