Nhắm mục tiêu: Commercial Buyers, Giám đốc nhà máy, and Engineering Contractors in Sand & Khai thác sỏi

1. Addressing Core Operational Challenges in Aggregate Production

Managing a sand and gravel operation requires balancing relentless production demands with stringent control over profitability. Industry data indicates that unplanned downtime and inconsistent product quality are primary drivers of eroded margins. Are you facing these specific challenges?

High Wear Part Costs & Điểm dừng đột xuất: Abrasive silica and aggregate materials degrade equipment rapidly. Frequent component failure on primary crushers or screens leads to production halts, costing an average of $1,800 per hour in lost output and emergency maintenance.
Inefficient Material Classification: Inaccurate sizing from underperforming screening equipment results in product contamination. This leads to load rejections, premium product being downgraded, and an inability to meet tight specifications for concrete or asphalt mixes.
Tạo tiền phạt quá mức & Yield Loss: Improper crushing chamber geometry or excessive crusher speed creates more fine material than marketable product, directly reducing the yield of highvalue coarse aggregates.
Tiêu thụ năng lượng cao trên mỗi tấn: Lớn hơn, nonoptimized crushing circuits can consume 3040% more power per ton of processed material, biến năng lượng thành chi phí hoạt động hàng đầu.
Rigid Plant Layout & Scalability Limits: Fixed conveyor systems and stationary primary units complicate site progression and make it difficult to economically process satellite deposits, limiting reserve life.

Câu hỏi trung tâm là: how can your operation increase throughput tonnage while simultaneously gaining control over costperton metrics?

2. Tổng quan về sản phẩm: HighCapacity Mobile Cone Crusher Plant

This solution is a trackmounted, closedcircuit cone crusher and screening plant designed for secondary and tertiary crushing in sand and gravel applications. It processes feed material from a primary crusher into precisely sized aggregates.

Quy trình hoạt động:
1. Chấp nhận nguồn cấp dữ liệu: Sized feed (tiêu biểu 5" / 125mm) from a primary jaw crusher is delivered via excavator or wheel loader into the integrated feed hopper.
2. ClosedCircuit Crushing & Định cỡ: Material is crushed in the highperformance cone crusher chamber. The entire output is conveyed to an onboard sizing screen.
3. Product Separation: The tripledeck screen separates output into multiple specification products (ví dụ., ¾" chip, cát bê tông, drain rock).
4. Tuần hoàn & Dự trữ: Oversize material is automatically recirculated back to the crusher inlet (closedcircuit operation). Onspec material is conveyed to designated stockpiles via radial conveyors.

Phạm vi ứng dụng & Hạn chế:
Phạm vi: Ideal for producing spec aggregates for road base, bê tông, nhựa đường, and drainage applications. Excels in processing hard, vật liệu mài mòn như đá granit, đá thạch anh, và sỏi sông.
Hạn chế: Not designed as a primary crusher for runofquarry shot rock exceeding recommended feed size. Optimal performance requires consistent feed gradation and controlled moisture content to prevent screen blinding.

3. Tính năng cốt lõi: Engineered for Aggregate Profitability

Thiết kế buồng nghiền tiên tiến | Cơ sở kỹ thuật: Laminated crushing principle with optimized kinematics | Lợi ích hoạt động: Produces a wellshaped, cubicle product with reduced flakiness index and controlled fines generation. | Tác động ROI: Increases saleable product yield by up to 15% by minimizing wasteful fines and improving particle shape for premium applications.

Onboard TripleDeck Screening System | Cơ sở kỹ thuật: Highfrequency vibration with adjustable screen angle and throw | Lợi ích hoạt động: Enables simultaneous production of up to four calibrated products in a single pass with high separation accuracy. | Tác động ROI: Eliminates the need for standalone screening plants, reducing capital outlay and improving overall site footprint efficiency.

Direct Hydraulic Drive System | Cơ sở kỹ thuật: Variablespeed hydraulic drive for the crusher and conveyors powered directly from the track engine | Lợi ích hoạt động: Eliminates Vbelts, reducers, and clutch components prone to wear and failure. Provides softstart capability and overload protection. | Tác động ROI: Lowers maintenance costs by an estimated 40% on drive components and reduces risk of catastrophic failure from tramp metal.

PLCBased Intelligent Control System | Cơ sở kỹ thuật: Automated process control with realtime feedback on crusher load, rút điện, và áp lực | Lợi ích hoạt động: Operators can optimize CSS (Cài đặt bên đóng) onthefly for different products; system autoregulates feed rate to prevent chamber overload. | Tác động ROI: Maximizes throughput while protecting the machine; reduces operator skill dependency and training overhead.

Theo dõi tính di động & Thiết lập nhanh | Cơ sở kỹ thuật: Heavyduty crawler tracks with hydraulic setup legs | Lợi ích hoạt động: Full plant relocation between processing zones or sites can be completed in under 30 phút bởi một nhà điều hành. | Tác động ROI: Enables efficient mining of multiple pit faces or contract processing at disparate sites with one machine fleet, maximizing asset utilization.

4. Lợi thế cạnh tranh

| Chỉ số hiệu suất | Tiêu chuẩn ngành (Nhà máy cố định / Older Mobile Design) | Mobile Cone Crusher Plant Solution | Lợi thế |
| : | : | : | : |
| Cài đặt / Relocation Time | 816 giờ (crew dependent) / 24 giờ | 80% sự cải tiến |
| Power Consumption per Tonne Crushed| ~2.1 kWh/t (secondary/tertiary stage)| ~1.7 kWh/t (fieldverified average)| ~19% improvement |
| Mặc một phần cuộc sống (Lớp lót mangan) | ~400k tonnes (variable based on abrasiveness) |>550nghìn tấn (in comparable abrasive feed) |>37% sự cải tiến |
| Năng suất sản phẩm (+4 Mesh Spec Material)| Đường cơ sở (~75%) |>85% with optimized chamber/screen combo |>13% increase in premium product |

5. Thông số kỹ thuật

Crusher Model: HighPerformance Cone Crusher
Recommended Maximum Feed Size: 125mm (5")
Crusher Drive Power: 300 kW (400 HP)
Tổng công suất lắp đặt (Thực vật): Tier IV Final / Stage V Compliant Diesel Engine
Hopper Capacity: 8m³ (10.5 yd³)
Main Discharge Conveyor: Belt width 1200mm (48"), Hydraulic folding & radial slew
Kích thước màn hình: Triple deck vibratory screen; area of each deck
Kích thước vận chuyển (L x W x H): Approximately Length x Width x Height
Operating Weight: ~50 tonnes
Phạm vi nhiệt độ hoạt động: 20°C đến +45°C (4°F đến +113°F)

6.Kịch bản ứng dụng

LargeScale Alluvial Gravel Operation

Thử thách: A Midwest producer needed higher onspec yield from very abrasive river gravel while reducing plant footprint to comply with wetland setbacks.
Giải pháp: Two mobile cone crusher plants were deployed in a parallel configuration downstream of primary jaws, replacing an aging fixed secondary circuit.
Kết quả: Yield of +¼" chip increased by 12%. The mobile setup allowed progressive pit advancement without conveyor reengineering. Fuel consumption dropped by an estimated $11k monthly across both units.

Granite Quarry Diversifying Product Lines

Thử thách: A quarry producing primarily road base sought to enter the concrete aggregate market but lacked precise sizing capability for washed chips.
Giải pháp: Integration of one mobile cone crusher plant equipped with a highfrequency wash screen as a dedicated tertiary circuit.
Kết quả: Enabled production of three new certified concrete stone products within six weeks of deployment without major site modification.Rejected loads due to gradation fell to near zero.

7.Cân nhắc thương mại

Equipment pricing is structured around configuration options that match your specific material profile:

• Base Configuration Tier includes core cone crusher plant with standard screening media suitable for most general aggregate duties.
• Premium Abrasion Package Tier adds upgraded wear liners,crusher automation,and heavyduty conveyor belts—recommended for operations processing highsilica materials (>70% SiO2).
• Integrated Washing Module Tier incorporates spray bars,sump,and dewatering cyclone(S),essential for producing specification mason or concrete sand.Optional features include remote monitoring telematics,dust suppression cannons,and magnet systems.Service packages range from basic scheduled maintenance plans(parts+labor)to comprehensive fullservice contracts covering wear parts.Financing options including operating leases,thỏa thuận thuê nhà phù hợp,and projectspecific capital loans are available through established partners.

8.Câu hỏi thường gặp

Q1:What upstream equipment is required?
A1.This unit functions as secondary/tertiary stage machinery.It requires consistent,sized feed typically provided by a tracked jaw crusher or large stationary primary.A wheel loader or excavator is used for charging the integrated hopper.

Q2:What are realistic production outputs?
A2.Tonnage varies significantly based on feed material hardness,crusher CSS setting,and desired product curve.In mediumhard abrasive gravel,a realistic spec range is between180250 tonnes per hour when producing two spec products plus recirculating load.Field data sheets are available upon request detailing specific test results.

Q3:Cần phải đào tạo người vận hành ở mức độ nào?
A3.The PLC control system simplifies operation.Basic training focuses on daily walkaround checks,screen media inspection/changing,and using the touchscreen interface.Most operators become proficient within three shifts.Comprehensive onsite training modules are included upon commissioning.

Q4:What does routine maintenance involve?
A4.Daily greasing intervals have been engineered out.The focus shifts to weekly visual inspections of wear liners,belt tracking,and hydraulic system checks.Oil sample analysis intervals are recommended at500hour increments.Predictive maintenance via remote monitoring further schedules interventions based on actual condition rather than fixed hours.

Q5:What lead time can we expect from order placement?
A5.For standard configurations,inventory allows delivery within810 weeks.Customconfigured units require1216 weeks lead time.A detailed project timeline will be provided upon application review