1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Are escalating operational costs and unpredictable downtime eroding your sand and gravel margins? Common industry challenges include:
High Maintenance & Component Wear: Thay thế lớp lót thường xuyên, màn hình, and pumps due to abrasive material flow directly increases parts inventory costs and labor hours.
Inefficient Material Classification: Inconsistent particle sizing leads to product rejection, reduces premium material yield, and forces reprocessing cycles.
Tiêu thụ năng lượng quá mức: Lớn hơn, nonoptimized crushing circuits and material handling systems consume disproportionate power per ton of final product.
Cấu hình nhà máy cứng nhắc: Fixed systems struggle to adapt to varying feed material hardness or changing product specification demands, hạn chế tính linh hoạt trong hoạt động.
Điểm dừng đột xuất: The cascading effect of a single component failure in the processing line can halt your entire operation, gây thiệt hại hàng ngàn mỗi giờ trong sản xuất bị mất.

Is your operation equipped to mitigate these risks while maintaining consistent quality and throughput? The foundation of a profitable aggregate business lies in specifying equipment engineered for durability, hiệu quả, and adaptability.

2. TỔNG QUAN SẢN PHẨM: HIGHCAPACITY SAND & GRAVEL PROCESSING PLANT

This modular sand gravel mining solution is a stationary or semimobile processing plant designed for highvolume aggregate production. It integrates primary crushing, secondary/tertiary reduction, precise screening, and material washing/classification into a coordinated system.

Quy trình hoạt động:
1. Giảm kích thước chính: Runofquarry feed is introduced to a robust primary jaw or impact crusher for initial size reduction.
2. Xử lý thứ cấp & Sàng lọc: Crushed material is conveyed to cone crushers or further impactors for shaping and cubical product generation, then screened via multideck vibratory screens.
3. giặt & Phân loại: Screened sand fractions are routed through cyclones or specialized sand screws to remove fines, contaminants, and achieve precise gradation.

Phạm vi ứng dụng: Ideal for largescale commercial aggregate mining operations supplying concrete asphalt plants, construction projects, and industrial uses. Suitable for processing granite, đá vôi, đá sông, and other similar aggregates.

Hạn chế: Not designed for ultrafine grinding (sub5mm specialty sands without modification) or highly contaminated industrial mineral processing. Site requires adequate space for plant footprint and settling ponds for water management.

3. TÍNH NĂNG CỐT LÕI

Khả năng chống mài mòn nâng cao | Cơ sở kỹ thuật: Highchrome alloy castings & modular wear component design | Lợi ích hoạt động: lót, impellers, and wear shoes demonstrate 3040% longer service life in abrasive silica applications | Tác động ROI: Reduces annual parts expenditure by an estimated 1825% and lowers maintenance labor requirements.

Hệ thống kiểm soát quy trình thông minh | Cơ sở kỹ thuật: Centralized PLC with loadmanagement algorithms and remote monitoring capability | Lợi ích hoạt động: Operators can optimize crusher pressure, feeder rates, and screen angles from a single station to maximize yield of spec product | Tác động ROI: Dữ liệu hiện trường cho thấy một 515% increase in throughput efficiency while reducing energy spikes.

Điều chỉnh thủy lực & Thanh toán bù trừ | Cơ sở kỹ thuật: Crusher settings and unblocking functions operated via integrated hydraulic systems | Lợi ích hoạt động: Enables rapid CSS adjustment for product size changes and clears chamber blockages in minutes without manual intervention | Tác động ROI: Minimizes downtime events; typical task time reduced from hours to under 30 phút.

MultiStage Washing & Khử nước | Cơ sở kỹ thuật: Counterflow design washing screen paired with highcapacity fine material washer/cyclone | Lợi ích hoạt động: Delivers clean, lowmoisture sand and gravel products that meet strict ASTM/CEN specifications for concrete work | Tác động ROI: Increases market value of final product by reducing clay/silt content; lowers water consumption per ton processed.

Băng tải mô-đun & Feed System | Cơ sở kỹ thuật: Customizable conveyor lengths/angles with impactresistant belts and sealed bearings | Lợi ích hoạt động: Provides reliable material transfer between stages with minimal spillage and dust generation in all weather conditions | Tác động ROI: Ensures consistent feed to critical crushers/screens; reduces cleanup costs and belt replacement frequency.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Điểm chuẩn tiêu chuẩn ngành | Our Sand Gravel Mining Solution Documented Performance | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Tons Processed per Wear Part Cost (USD) | $1.50 $2.00 mỗi tấn (đá mài mòn) <$0.85 $1.10 mỗi tấn Improved by ~35% |
| Electrical Power Consumption (kWh/tấn) <6 8 kWh/tấn <5 6 kWh/tấn Improved by ~20% |
| OnSpec Product Yield (Crushed Aggregate) 92 95% Năng suất Improved by ~57% |
| Thời gian trung bình giữa thất bại (Critical Path) 800+ Giờ Improved by ~50% |

5. THÔNG SỐ KỸ THUẬT

Design Capacity Range: Có thể cấu hình từ 200 đến hơn 800 tấn mỗi giờ (TPH), depending on feed material hardness (ví dụ., Đá granit vs. Đá vôi) and final product mix.
Tùy chọn máy nghiền chính: lời nguyền hàm (900 x 1200mm to 1500 x 2000mm feed opening) or Primary Impact Crusher (rotor diameter up to 1800mm).
Giai đoạn cấp hai/đại học: Hydraulic Cone Crushers with multiple chamber options; crusher power up to 500 kW.
Screening Units: Heavyduty vibrating screens up to 3 decks; sizes from 2.4m x 6m to 3m x 8m.
Material Washing System: Dual sand screw units (up to 36” diameter x 35’ length) or cyclone clusters capable of processing up to 250 TPH of fines.
Yêu cầu về nguồn điện: Tổng công suất lắp đặt của nhà máy thường dao động từ 800 kW đến hơn 2000 kW for maximum capacity configurations. Designed for highvoltage grid connection.
Thông số kỹ thuật vật liệu chính: Mainframe constructed from hightensile steel plate; critical wear components utilize TENSALOY™ AR400/500 steel or equivalent highchrome white iron alloys.
Phạm vi hoạt động môi trường: Được thiết kế cho nhiệt độ môi trường xung quanh từ 20°C đến +50°C (4°F đến +122°F). Dust suppression systems are integral; noise levels comply with standard industrial regulations.

6. KỊCH BẢN ỨNG DỤNG

LargeScale Commercial Aggregate Producer

Challenge A Midwest producer supplying state highway projects faced inconsistent gradation from their aging wash plant leading 15% rejection rates on certain sand products frequent pump failures causing weekly downtime
Solution Implementation of a complete turnkey sand gravel mining plant featuring advanced cyclonic classification slurry pumps with oversized wear components
Results Within six months onspec product yield increased by 12%. Pumprelated stoppages decreased by 80%. The producer secured a premium contract based on consistent quality certification

Transition from PitRun to HighValue Concrete Aggregates

Challenge A familyowned quarry selling primarily pitrun material sought higher margins but lacked the washing precise crushing capability needed for concrete aggregate markets
Solution A modular midrange configuration focusing on tertiary crushing for cubicity a highefficiency fine material washer/dewaterer
Results The operation now produces three new certified products—concrete sand pea gravel 57 stone—increasing overall revenue per ton by over 35%. The modular design allowed phased implementation within an existing site plan

7 CÂN NHẮC THƯƠNG MẠI

Pricing is projectspecific based on required capacity final product slate level of automation

Standard Plant Tiers:
Tier I EntryLevel Stationary Plant Capable of 250 TPH throughput focusing on basic crushed stone production Available as bare equipment package
Tier II Advanced Processing Plant Upgraded wear packages process control automation washing modules Throughput 450 TPH Includes commissioning supervision
Tier III HighCapacity Turnkey System Fully integrated circuit including dust suppression water recycling advanced instrumentation Throughput 800+ TPH Includes extended operator training performance guarantee

Optional Features Premium ceramic wear liners remote telematics package automated greasing systems hybrid diesel/electric drive options

Service Packages Available Comprehensive multiyear maintenance agreements guaranteed parts availability programs scheduled technical audits

Financing Options Flexible capital expenditure solutions include traditional equipment leasing longterm rental with purchase option project financing support

8 Câu hỏi thường gặp

What if my feed material hardness changes frequently?
The hydraulic adjustment on core crushers allows you modify closedside settings CSS in under ten minutes adapting the circuit produce different spec products without major mechanical changes

How does this system manage water consumption environmental compliance?
The closedloop water management system optional recirculates up 90% process water significantly reducing freshwater intake volume Sludge handling systems are designed integrate standard settling ponds filter press systems

What is typical installation commissioning timeline?
For a Tier II system site preparation civil works require approximately weeks Factory preassembled modules reduce onsite erection time Commissioning performance validation typically takes another weeks supervised our engineers

Phụ tùng thay thế có sẵn không?
We maintain regional inventory hubs critical wear components Structural parts are sourced global network suppliers ensuring lead times rarely exceed standard industry norms even nonstandard items

Bạn có cung cấp bảo đảm hiệu suất?
Yes Tier II III solutions include guaranteed minimum throughput capacity based agreed feed material specifications specific power consumption targets These are validated during acceptance testing period