1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Chi phí hoạt động ngày càng tăng và thời gian ngừng hoạt động không thể đoán trước đang làm xói mòn biên lợi nhuận sản xuất tổng hợp của bạn? Dành cho người quản lý nhà máy và nhà thầu kỹ thuật, the core challenges in material reduction often stem from inefficient primary crushing. Điểm đau phổ biến bao gồm:
Thời gian ngừng hoạt động quá mức để bảo trì: Frequent liner changes and unplanned repairs on your primary crusher halt your entire processing line, gây thiệt hại hàng ngàn mỗi giờ trong sản xuất bị mất.
Giảm kích thước nguồn cấp dữ liệu không nhất quán: Variable feed material causes chokefeeding or erratic performance, leading to downstream bottlenecks in your secondary and tertiary circuits.
Chi phí hoạt động cao: Soaring energy consumption per ton of processed material and premature wear part failure directly impact your bottomline profitability.
Limited Flexibility & Khả năng mở rộng: A fixed crushing solution cannot adapt to changing feed materials or increased production targets without significant capital reinvestment.

Is your primary crushing station the bottleneck in your operation? Điều gì sẽ 1520% reduction in costperton mean for your annual budget? The solution lies in specifying a highperformance, reliable primary crushing station engineered for maximum uptime and efficiency.

2. TỔNG QUAN SẢN PHẨM: PRIMARY CRUSHING STATION

A Primary Crushing Station is a complete, semifixed or modular system designed for the first stage of size reduction in quarrying, khai thác mỏ, and largescale construction applications. Its function is to accept runofmine or blasted feed material (up to 1000mm+) and reduce it to a conveyable size for transport to downstream processing.

Quy trình hoạt động:
1. Cho ăn & Sàng lọc trước: Dump trucks deposit material into a robust vibrating grizzly feeder (VGFF VGF).
2. Giảm sơ cấp: The VGF scalps fines and directs oversize material into a highcapacity jaw crusher or gyratory crusher for initial compression breaking.
3. Xử lý vật liệu: Crushed product is discharged onto a main conveyor belt system for transport to the next stage of processing.

Phạm vi ứng dụng: Ideal for hightonnage hard rock (đá granit, đá bazan), quặng mài mòn, and recycled concrete operations requiring throughput from 500 đến hơn 2,500 tph.

Hạn chế: Not suitable as a standalone solution where final product specification is required; must be integrated with secondary/tertiary crushing and screening circuits. Site requires adequate space for setup and feed access.

3. TÍNH NĂNG CỐT LÕI

Patented Quarry Jaw Design | Cơ sở kỹ thuật: Động học tối ưu & reinforced chamber geometry | Lợi ích hoạt động: Achieves higher reduction ratios with lower wear rates, minimizing frequency of liner changes | Tác động ROI: Reduces wear part inventory costs by an estimated 18% and increases crusher availability

HeavyDuty Modular Base Frame | Cơ sở kỹ thuật: tiền chế, bolttogether substructure with integral walkways | Lợi ích hoạt động: Enables faster site installation and future relocation without heavy fabrication work | Tác động ROI: Giảm thời gian cài đặt lên tới 40%, accelerating timetoproduction

Intelligent Variable Speed Feeder Control | Cơ sở kỹ thuật: PLCdriven VGF with loadsensing technology | Lợi ích hoạt động: Automatically regulates feed rate to prevent crusher overload (choke) or underutilization (starve) | Tác động ROI: Optimizes power draw, improving energy efficiency by up to 12% and maximizing throughput

Hệ thống khử bụi tích hợp | Cơ sở kỹ thuật: Strategically placed nozzle arrays with solenoid control tied to crusher operation | Lợi ích hoạt động: Actively suppresses dust at key transfer points only when needed, conserving water | Tác động ROI: Ensures regulatory compliance while reducing water consumption by approximately 30%

Bôi trơn tập trung & Lube Station | Cơ sở kỹ thuật: Singlepoint connection for automated lubrication of all major bearings | Lợi ích hoạt động: Cho phép an toàn, routine maintenance from one location in under 15 phút | Tác động ROI: Enhances bearing life by ensuring consistent lubrication, preventing costly failures

HighStrength Discharge Conveyor | Cơ sở kỹ thuật: Channel frame design with impact bars at loading zone | Lợi ích hoạt động: Withstands continuous heavy loads and direct impact from crushed discharge | Tác động ROI: Reduces belt damage and spillage, lowering conveyor maintenance costs

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Điểm chuẩn tiêu chuẩn ngành | Our Primary Crushing Station Solution | Lợi thế được ghi lại |
| : | : | : | : |
| sẵn có (Thời gian chạy theo lịch trình) | 8892% | 95%+| +47% Sự cải tiến |
| Chi phí mỗi tấn (Mặc bộ phận) | Đường cơ sở (100%)| 85%| 15% Sự giảm bớt |
| Cài đặt & Thời gian vận hành| 810 Tuần| 56 Tuần| ~40% Faster Deployment |
| Tiêu thụ năng lượng (kWh/tấn)| Khác nhau tùy theo loại đá| Lên đến 12% Thấp hơn| Verified by field telemetry |
| Thời gian trung bình giữa thất bại (MTBF)| ~1,200 hours| >1,600 giờ| +33% Reliability Increase |

5. THÔNG SỐ KỸ THUẬT

Loại máy nghiền: HeavyDuty Single Toggle Jaw Crusher
Mở nguồn cấp dữ liệu: 1,400mm x 1,200mm (55" x 47")
Kích thước nguồn cấp dữ liệu tối đa: 1,000mm (39")
Cài đặt bên đóng (CSS) Phạm vi: 150mm 300mm (6" 12")
Phạm vi công suất: Lên đến 900 1,200 tph (phụ thuộc vào mật độ vật liệu & CSS)
Ổ điện: Tier IV Final / Stage V compliant dieselelectric or direct electric drive options; 200 kW main crusher motor.
Chế tạo kết cấu: Hightensile steel plate with abrasionresistant liners at critical wear points.
Station Footprint (Dài x Rộng): Approximately 28m x 8m (92' x 26').
Phạm vi nhiệt độ hoạt động: 25°C đến +45°C (13°F đến +113°F) with appropriate fluid specifications.

6. KỊCH BẢN ỨNG DỤNG

Dự án mở rộng mỏ đá granite

Challenge A granite producer needed to increase plant throughput by 35% but was constrained by an aging primary crusher causing 10 hours of weekly unplanned downtime.
Solution Implementation of our modular Primary Crushing Station with the patented jaw design and intelligent feeder control.
Results Station commissioned in 5 tuần. Đạt được sản lượng bền vững 950 tph with availability exceeding 96%. Costperton reduced by 18%, paying back the investment in under 14 tháng.

LargeScale Infrastructure Development

Challenge A civil engineering contractor required a temporary highvolume crushing solution for processing excavated basalt on a major highway project, with strict dust control regulations.
Solution Deployment of a mobileprimarycrusherconfigured station with integrated dust suppression and quickrelocation capability.
Results The station processed over 2 million tons of material onsite across three different project phases. Dust emissions remained within compliance limits without slowing production, eliminating offsite hauling costs.

7. CÂN NHẮC THƯƠNG MẠI

Our Primary Crushing Stations are offered in three capabilitybased tiers:
Essential Tier: Highreliability core system ideal for consistent feed materials. Base pricing structured around required throughput capacity.
Cấp hiệu suất: Includes advanced features like intelligent feeder control, automated lubrication,and enhanced dust suppression for operations targeting optimal costperton.
Elite Tier: Fully customized stations with premium components,surge capacity design,and predictive maintenance telemetry integration for megaprojects.

Optional features include onboard power generation sets,magnet systems for tramp metal removal,and heated operator stations.Service packages range from basic commissioning support to comprehensive Planned Maintenance Agreements covering parts,nhân công,và kiểm tra theo lịch trình. Các lựa chọn tài chính bao gồm các hợp đồng cho thuê vốn,cấu trúc cho thuê phù hợp,và tài trợ theo dự án thông qua các đối tác được công nhận.

8. Câu hỏi thường gặp

Q1 Is this Primary Crushing Station compatible with my existing secondary plant?
A Yes.The discharge conveyor speed heightand load capacity are engineered during specificationto match your downstream receiving hopper or screen feed conveyor ensuring seamless integration.

Q2 What is the expected operational impact during liner changes?
A Our jaw design features hydraulic setting adjustmentand reversible liners.Field data shows liner changeout can be completed typically within one standard shift minimizing production loss comparedto older designs requiring longer downtime

Q3 Are there financing options available that alignwith our project cash flow?
A Yes.We offer several commercial structures including operating leases that preserve capitaland milestonebased payment plans tiedto commissioningand performance verification

Q4 How does the intelligent feeder control handle highly variable feed material?
A The PLC system monitors crusher power drawin realtime automatically slowingor speedingthe feeder tomaintain optimal chamber loading This protects the crusherfrom tramp metal eventsand mitigates the effectsof size variation

Q5 What trainingis providedfor our maintenance crew?
A Comprehensive trainingis included covering daily inspections routine maintenance proceduresand wear part replacement protocols Documentation includes detailed manualsand troubleshooting guides