1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Are you managing a stone quarry operation where inconsistent feed, thời gian ngừng hoạt động ngoài kế hoạch, and rising operational costs are eroding your margins? Key challenges in primary crushing include:

Thời gian ngừng hoạt động quá mức để bảo trì: Frequent liner changes and unexpected component failures in the primary crusher can halt your entire processing line for hours, costing thousands in lost production per event.
Chi phí bộ phận hao mòn cao: Abrasive feed material leads to rapid wear of crusher jaws, áo choàng, và lõm, creating a significant and recurring expense for your parts inventory.
Thông lượng không nhất quán & Phân cấp sản phẩm: Fluctuations in feed size or hardness can cause chokefeeding or poor cavity utilization, resulting in suboptimal tonnage and offspec product that requires recrushing.
Năng lượng kém hiệu quả: Older or poorly configured crushing plants consume excessive power per ton of processed material, tác động trực tiếp đến lợi nhuận của bạn khi chi phí năng lượng tăng lên.
Mối quan tâm về tính toàn vẹn của cấu trúc: The immense forces generated in a primary crushing station demand a fabricated structure of exceptional durability. Inadequate design can lead to costly frame fatigue, cracks, and alignment issues over time.

How do you select a crushing plant fabricator that not only provides robust equipment but also delivers the operational reliability and total cost of ownership metrics that your business requires?

2. TỔNG QUAN SẢN PHẨM: ISOCertified Stationary Primary Crushing Plant

We engineer and fabricate heavyduty, stationary primary crushing plants designed as the cornerstone of hard rock quarry operations. These turnkey solutions are built to receive blasted feed from haul trucks and reduce it to a consistent, sản phẩm có thể chuyển tải để xử lý thứ cấp.

Quy trình hoạt động:
1. Cho ăn & Sàng lọc trước: mỏ đá Runof (ROQ) material is dumped into a rugged vibrating grizzly feeder (VGFF VGF), which scalps out fine undersize material to bypass the crusher, nâng cao hiệu quả.
2. Giảm kích thước chính: Oversize material is directed into a highcapacity jaw crusher (hoặc máy nghiền hồi chuyển, depending on application) nơi nó bị nén và gãy trên các bề mặt cố định và chuyển động.
3. Vận chuyển sản phẩm: Crushed material is discharged onto a heavyduty main product conveyor, transporting it to the next stage of the processing circuit.

Phạm vi ứng dụng: Ideal for hightonnage processing of granite, đá bazan, đá vôi, và các cốt liệu mài mòn khác. Suited for permanent installation in largescale quarry operations.

Hạn chế: Không được thiết kế cho các ứng dụng di động hoặc di động. Maximum feed size is determined by crusher model selection; extremely sticky or claybound materials may require additional preprocessing.

3. TÍNH NĂNG CỐT LÕI

Modular Fabricated Base Frame | Cơ sở kỹ thuật: CADTối ưu hóa, highstrength steel weldment with internal reinforcing diaphragms | Lợi ích hoạt động: Provides an unwavering foundation that maintains precise crusher and motor alignment under cyclical loading | Tác động ROI: Eliminates costly realignment downtime and extends bearing & drive component life by up to 30%.
Nền tảng bảo trì tích hợp & Truy cập | Cơ sở kỹ thuật: Ergonomic design per ISO safety standards with nonslip grating, guardrails, and strategic service points | Lợi ích hoạt động: Your crew can perform routine inspections, liner checks, and maintenance tasks safely and efficiently | Tác động ROI: Reduces service time by an average of 25%, giảm chi phí lao động và tăng tính sẵn có của nhà máy.
Máy cấp liệu Grizzly rung hạng nặng (VGFF VGF) Phần | Cơ sở kỹ thuật: Robust deck construction with replaceable grizzly bars and highinertia vibrator motors | Lợi ích hoạt động: Effectively removes fines while absorbing direct impact from haul truck dumping | Tác động ROI: Increases primary crusher capacity by preventing chokefeeding with fines; bảo vệ máy nghiền khỏi tải sốc.
Dầu bôi trơn tập trung & Hệ thống thủy lực | Cơ sở kỹ thuật: Manifolded system with failsafe indicators and easyaccess service ports | Lợi ích hoạt động: Cho phép an toàn, lau dọn, and consistent lubrication of all critical crusher bearings from a single location | Tác động ROI: Standardizes maintenance procedures prevents lubrication failures which are a leading cause of major component damage.
Cable Management & Utility Routing | Cơ sở kỹ thuật: Prefabricated steel conduits and trays integrated into the plant structure | Lợi ích hoạt động: Protects power and control cables from damage dust contamination ensuring reliable electrical supply | Tác động ROI: Minimizes electrical faults reduces installation time onsite by providing a plugandplay wiring infrastructure.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Thực hành tiêu chuẩn ngành | Our ISOCertified Crushing Plant Solution | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Structural Durability (Fatigue Life) | Fieldwelded fabrication with variable quality control; potential for stress points. | Plantwide FEA analysis; precision shopwelding under controlled conditions per ISO 38342. +40% estimated service life before major refurbishment. |
| Cài đặt tại chỗ & Thời gian vận hành| 46 weeks for foundation work assembly alignment testing. Modular design with preassembled sections; laseraligned at factory. 50% onsite labor time reduced project risk. |
| Sẵn sàng hoạt động (Thời gian hoạt động) ~92% based on typical maintenance schedules unplanned stops.| >95% documented via telemetry from installed units optimized access predictive maintenance design.| +3 percentage points translating to significant annual tonnage gains. |
| Tiêu thụ năng lượng trên mỗi tấn được xử lý| Varies widely older drives directonline starting.| Engineered drive train efficiency softstart systems optimized kinematics.| Dữ liệu hiện trường hiển thị 815% giảm tiêu thụ năng lượng cụ thể |

5. THÔNG SỐ KỸ THUẬT

Phạm vi công suất: Configurable for throughputs from 400 ĐẾN 2 000+ tấn mỗi giờ (TPH)
Tùy chọn máy nghiền chính: lời nguyền hàm (900 x 1200mm đến 1500 x 2000mm) hoặc Máy nghiền con quay sơ cấp
Grizzly Feeder: Chiều rộng từ 1 200mm đến 2 400mm; độ dài từ 4 500mm đến 7 500mm
Yêu cầu về nguồn điện: Tổng công suất lắp đặt thường từ 250 kW 600 kW phụ thuộc vào cấu hình
Thông số vật liệu: Main frame fabricated from S355JR structural steel; wear surfaces utilize AR400 abrasionresistant steel liners
Kích thước vật lý (Đặc trưng): Approximate footprint of 18m (L) x 8m (W) x 9m (H). Custom designs available
Environmental Operating Range Designed for ambient temperatures from 20°C to +45°C dust moisture conditions typical of outdoor quarry operation

6. KỊCH BẢN ỨNG DỤNG

Granite Quarry Expansion Southeast Asia Challenge A major quarry needed to double primary circuit capacity but had limited space for new foundations faced stringent noise/vibration regulations Solution A compact highcapacity jaw crusher plant was designed with an integrated acoustic enclosure vibrationisolation pads mounted on a single deeppile foundation Results Achieved target throughput of 1 200 TPH within existing site footprint community noise complaints reduced by 60%

Basalt Processing Plant Upgrade North America Challenge Chronic downtime due to frame fatigue cracks poor accessibility for mantle changes on an aging primary station Solution Complete replacement with a customfabricated primary plant featuring reinforced modular base walkin maintenance platforms around the crusher Results Mantle changeout time reduced from 36 giờ để 14 hours no structural integrity issues reported after 3 years of continuous operation

7 CÂN NHẮC THƯƠNG MẠI

Our ISOcertified fabrication process ensures transparent costing predictable delivery schedules

Bậc giá
1 Base Plant Includes fabricated structure VGF crusher mounting main discharge conveyor walkways ladders
2 Premium Package Adds centralized automated lube system integrated dust suppression spray system premium motor starters
3 Turnkey Pro Includes full electrical control package PLC instrumentation advanced condition monitoring sensors

Optional Features Acoustic cladding special coatings for corrosive environments custom feed hopper designs belt scales metal detection

Service Packages Extended warranty plans scheduled inspection services remote performance monitoring subscriptions wear part supply agreements

Financing Options Available through partner institutions including equipment leasing longterm rental plans tradein options for existing assets

8 Câu hỏi thường gặp

Mức độ chuẩn bị mặt bằng cần thiết trước khi giao hàng?
We provide detailed foundation drawings load data anchor bolt templates Your contractor prepares the civil works according to our specifications ensuring our team can commence efficient mechanical erection

How does your fabrication quality control impact longterm reliability?
Our ISO 9001 38342 certifications mandate documented procedures for material traceability welding qualifications dimensional checks This systematic approach eliminates defects that cause premature failure ensuring predictable lifecycle costs

Can this plant be integrated with my existing secondary circuit conveyor?
Yes Our design team will engineer the discharge height conveyor speed transfer point to match your existing system specifications We ensure seamless material flow integration

Thời gian thực hiện thông thường từ khi đặt hàng đến vận hành là bao lâu?
Lead times vary based on project scope complexity A standard configured plant typically has a 68 month timeline including engineering procurement fabrication testing disassembly shipping Site commissioning requires approximately 34 weeks with our supervision

Do you provide operational training for our crew?
Yes Comprehensive training covering safe operation routine maintenance procedures basic troubleshooting is provided during commissioning Documentation includes detailed operation maintenance manuals