Transportable Bulk Material Plant Modular Deployment
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Solution Overview
Problem
Existing bulk material processing plants face challenges in harsh environments due to exposed electrical and hydraulic power supplies, leading to degradation and high logistical costs, with significant downtime for conveyor repairs and lengthy installation processes.
Innovation Solution
A transportable bulk material processing plant with modular crusher and screening machines, supported by detachable legs, featuring on-board power and control systems, allowing for rapid deployment and reduced personnel requirements, with the ability to be transported and assembled at remote sites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If individual crusher machines and screening machines are installed at a fixed purpose-built site with external power and control supplies, then the processing capacity is sufficient, but the installation time and logistical costs are considerable
Solution Approach 1:
The processing plant is divided into modular units (crusher modules, screening modules, conveyor modules) that can be independently manufactured, transported, and assembled. Each module contains integrated components including machinery, power supplies, and control systems, enabling rapid deployment without extensive site preparation while maintaining full processing capacity.
2Power
If electrical and hydraulic power supplies are installed in external containers or buildings with external connections, then the power capacity is sufficient, but the supplies are exposed to harsh conditions and at risk of degradation and damage
Solution Approach 1:
Power supplies, control systems, and the machinery they serve are integrated into single weatherproof modular units. This consolidation protects electrical and hydraulic components from harsh environmental conditions while ensuring adequate power capacity for each module's operations.
Solution Approach 2:
Weatherproof enclosures and protective housings serve as intermediaries between the electrical/hydraulic components and the harsh external environment, shielding sensitive supplies from dust, moisture, and temperature extremes while maintaining functional connectivity.
3Productivity
If individual machines are installed separately with external power connections, then the processing functionality is complete, but the number of personnel and site works required are considerable
Solution Approach 1:
The plant is segmented into self-contained modules that each perform specific processing functions independently. This modular architecture simplifies installation by reducing the number of site works required, as modules can be pre-assembled and tested before deployment, thereby maintaining complete processing functionality with reduced personnel requirements.
Solution Approach 2:
Each modular unit is designed as a self-service package containing all necessary components (machinery, power supply, control system) required for independent operation. This self-contained design reduces installation complexity by eliminating the need for extensive external connections and site preparation work.
4Productivity
If conveyors are installed between crusher machines at a fixed site, then the material transport capability is sufficient, but the downtime for conveyor repairs is significant
Solution Approach 1:
Conveyors are integrated as modular components within or between processing modules, allowing them to be easily detached, replaced, or repaired without shutting down the entire plant. This segmented approach maintains material transport capability while minimizing repair downtime through rapid module interchangeability.
Data Source
AI summary
A transportable bulk material processing plant (10) provides at least one of a crusher module (12) or a screening module (14). At least one of the modules has a transportable platform (16.1) supporting at least one respective crusher (18) screening machine (20). Supports (22), such as legs, support the respective platform (16.1) on the ground or on a base (24). The supports (22) can be unfastened from the structure of the platform (16.1) and the platform and supports can be transported, such as by sea, road or rail, for erection at a work site. A removable conveyor module (38) can be provided/inserted under the platform for receiving crushed/comminuted material. Crushed material from one of the crusher machines can be supplied via the conveyor (36) to a screening module (14). Retaining walls (40) can retain earth and can be pivotably attached to the structure of the crusher module. The respective module (crushing or screening module) can include an on-board power system and/or an on-board control system, such as at an on-board MCC (66) to control electric motors for the module.