Export Quarry Ballast Crushing Equipment Quotation
معدات تكسير صابورة المحاجر المستهدفة: تم تصميمه لتحقيق أقصى إنتاجية والحد الأدنى من وقت التوقف عن العمل
1. فتحة مدفوعة بنقطة الألم
إنتاج متسقة, تعتبر صابورة السكك الحديدية ذات المواصفات المحددة محركًا أساسيًا لربحية المحاجر, yet the crushing process presents persistent operational challenges. هل تواجه:
توليد الغرامات المفرطة: حتى 20% of processed material can fall below the required gradation, turning potential revenue into lowvalue byproduct.
التوقف غير المخطط له: Frequent liner changes and wear part failures in abrasive granite, البازلت, or gneiss applications halt your primary production line for costly maintenance windows.
شكل المنتج غير متناسق: Poor cubicity and excessive flaky material in your ballast product can lead to rejection by rail authorities, requiring recrushing and stockpiling issues.
تكاليف تشغيلية عالية: Rising energy consumption per ton and the cumulative expense of rapid wear part consumption directly erode your margin on every cubic meter of ballast shipped.
Rigid Process Flow: Inflexible crusher settings struggle to adapt to natural variations in feed stone size or hardness, causing bottlenecks and quality control headaches.
السؤال المركزي لمديري المصانع هو هذا: how can you increase the percentage of highvalue, inspec ballast while systematically reducing cost per ton and unplanned stoppages?
2. نظرة عامة على المنتج
Our dedicated quarry ballast crushing equipment is a highperformance cone crusher series specifically configured for secondary and tertiary reduction of hard, abrasive aggregates into railway ballast. The operational workflow is designed for integration into existing plant layouts:
1. Primary Feed Reception: Accepts screened oversize material (+40مم) from your primary jaw or gyratory crusher.
2. تخفيض الدقة: Utilizes a combination of high inertia and an optimized crushing chamber geometry to fracture stone along natural lines.
3. تشكيل المنتج: Interparticle comminution within a packedbed chamber promotes the production of cubic, wellshaped particles critical for ballast interlock.
4. التحكم في التدرج: التعديل الهيدروليكي لإعداد الجانب المغلق (CSS) allows realtime tuning to meet exacting BS, أريما, or local rail specifications (على سبيل المثال, 5025مم).
5. Direct Discharge: Crushed product is conveyed to final screening decks, minimizing chip rehandling and degradation.
نطاق التطبيق & القيود:
مثالية ل: Secondary/tertiary crushing of granite, صخرة فخ, البازلت, and other high PSI (250+ MPa) aggregates for railway ballast and construction armor stone.
القيود: Not designed as a primary crusher for runofquarry material exceeding a top size of 250mm. Not suitable for processing recycled concrete or asphalt (موسيقى الراب/RCA) without significant configuration changes.
3. الميزات الأساسية
تعديل Hydroset CSS | الأساس الفني: Hydraulic piston supporting main shaft | المنفعة التشغيلية: Operators can adjust crusher gap settings in under 60 seconds from a remote location for precise gradation control. | تأثير عائد الاستثمار: يلغي توقف الإنتاج لإجراء تعديلات يدوية على الرقائق, زيادة توافر النباتات بنسبة تقدر 23%.
غرفة سحق متعددة الطبقات | الأساس الفني: Optimized feed opening, parallel zone length, and throw profile | المنفعة التشغيلية: Creates a rockonrock crushing action that reduces liner wear by up to 30% on abrasive stone while enhancing particle shape cubicity. | تأثير عائد الاستثمار: Lowers costperton for manganese steel consumables and improves saleable product yield.
تعويض التآكل الآلي | الأساس الفني: PLCintegrated system monitoring hydraulic pressure and piston position | المنفعة التشغيلية: Automatically maintains the preset closedside setting as liners wear, ensuring consistent product gradation throughout the liner lifecycle without manual intervention. | تأثير عائد الاستثمار: Reduces product quality variation by over 70%, virtually eliminating offspec batches.
High Inertia AntiFriction Bearings | الأساس الفني: Largediameter heavyduty roller bearings supporting eccentric assembly | المنفعة التشغيلية: Sustains high crushing forces with lower friction losses than bushingtype designs, handling peak loads from uncrushable material via tramp release. | تأثير عائد الاستثمار: تظهر البيانات الميدانية أ 1520% تخفيض في استهلاك الطاقة المحددة (كيلوواط ساعة/طن) compared to older crusher designs.
نظام الاحتفاظ بالبطانة | الأساس الفني: Mechanically locked backing compound and boltin design | المنفعة التشغيلية: Secures mantle and concave liners firmly, preventing movement that causes premature fatigue failure and reducing liner changeout time by up to 40%. | تأثير عائد الاستثمار: Shortens planned maintenance downtime directly impacting annual throughput capacity.
4. المزايا التنافسية
| مقياس الأداء | معيار الصناعة (كسارة مخروطية متوسطة) | حل تكسير صابورة المحاجر الخاص بنا | ميزة (% تحسين) |
| : | : | : | : |
| Saleable Ballast Yield (% من العلف) | 6575% | 7885%| +10 ل +15% |
| حياة الخطوط الملاحية المنتظمة (Operating Hours Granite) | 800 1,200 ساعة| 1,400 1,800 ساعة| +40% |
| استهلاك الطاقة (kWh per ton output)| Based on historical plant data| Configurable based on model selection| حتى 20% |
| اتساق التدرج (الأمراض المنقولة جنسيا. Deviation in CSS)| High variation over liner life| Maintained within ±2mm via automation| +70% تناسق |
| متوسط الوقت بين الفشل (MTBF)| ~ 1500 ساعة| يوضح اختبار الصناعة >2,200 ساعات| +30% مصداقية |
5. المواصفات الفنية
سعة نطاق النموذج: 150 - 800 طن في الساعة (الهيدروكربونات النفطية في الساعة) of finished ballast product (50مم + 25 مم), depending on chamber selection and feed material.
متطلبات الطاقة: محرك كهربائي من 150 كيلوواط ل 400 كيلوواط. All models include softstart capability for reduced electrical network stress.
مواصفات المواد: إطار رئيسي من الفولاذ المصبوب عالي الجودة; Austenitic manganese steel wear liners standard; Optional chromewhite iron liners available for specific highly abrasive feeds.
الأبعاد المادية (نموذج نموذجي): تقريبا. طول: 4م × العرض: 3م × الارتفاع: 3م (باستثناء قادوس التغذية). Weight ranges from ~18 to ~45 tonnes.
نطاق التشغيل البيئي: مصمم لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +45 درجة مئوية مع مواد التشحيم المناسبة. Dust sealing is rated IP67 standard.
6. سيناريوهات التطبيق
محجر هارد روك يزود مشروع السكك الحديدية الوطنية | تحدي: A granite quarry’s existing secondary crusher produced over 22% fines when making Type A ballast, creating a significant waste stream during a highvolume infrastructure project.| حل: Implementation of our HPCseries quarry ballast crushing equipment with a coarseliner chamber profile.| نتائج: تم تخفيض توليد الغرامات إلى أقل من ذلك 14%, increasing saleable yield by over 8%. The automated wear compensation maintained gradation compliance across weekly quality audits with zero nonconformance reports.
Regional Aggregate Producer Expanding Market Reach | تحدي: Need to produce both premium railway ballast and construction aggregate from the same plant without sacrificing flexibility or incurring excessive changeover downtime.| حل: Installation of our multichamber capable cone crusher with two interchangeable liner sets.| نتائج: Changeover between rail spec aggregate and road base spec is achieved in one scheduled 8hour shift versus 24 hours previously required for major reconfiguration. This enabled the producer to service both markets competitively.
7. الاعتبارات التجارية
Our quarry ballast crushing equipment is offered in three primary tiers:
تكوين الواجب القياسي: For consistent feed materials. يشمل كسارة الأساسية, محرك السيارة, نظام التشحيم الأساسي, and manual controls.
تكوين التوفر العالي: Adds automated wear compensation PLC system advanced dust seals heavyduty filtration package remote monitoring ports
Turnkey Modular Skid Package: Crusher premounted on a structural steel skid complete with integrated feeders conveyors walkways safety systems
تشمل الميزات الاختيارية:
Metal detection automatic tramp release systems
Lubrication oil condition sensors
تكامل برامج الصيانة التنبؤية المتقدمة
Service packages range from annual inspection plans comprehensive longterm performance contracts including guaranteed parts availability financing options include equipment leasing capital loans through partner institutions tailored payperton agreements
8.التعليمات
Q What primary crusher feed size is compatible with your quarry ballast crushing equipment?
A For optimal performance we recommend a maximum feed size not exceeding 250mm ideally prescreened at 40mm This ensures efficient operation prevents chokefeeding
Q How does this equipment impact our overall plant throughput?
A By increasing saleable yield reducing unplanned downtime field data typically shows net plant throughput increases between 5 15 depending on existing circuit limitations
س هل الأجزاء القابلة للتآكل متاحة بسهولة؟?
A We maintain regional inventory hubs stock all critical wearing parts including mantles concaves bushings Standard delivery lead times are under 72 hours supported by guaranteed supply agreements
Q What are typical installation requirements?
A The unit requires prepared concrete foundations adequate craneage lifting capacity electrical connection per model specifications Our engineering team provides full foundation drawings load data
Q Can we finance this equipment under an operating expense OpEx model?
A Yes we offer several flexible arrangements including rental leasetoown contracts based on monthly throughput volumes allowing you preserve capital expenditure CapEx budgets