أسعار منتجي تعدين الحجر الجيري
1. فتحة مدفوعة بنقطة الألم
Managing the cost and efficiency of primary size reduction is a persistent challenge in limestone quarrying and processing. Inconsistent feed, abrasive material, and unplanned downtime directly erode your profit margins. Are you facing these specific operational hurdles?
High Cost of Comminution: Crushing is the single most energyintensive stage in your plant. Inefficient equipment can increase your costperton by 1525% through excessive power draw and premature wear part consumption.
Unplanned Downtime for Maintenance: The abrasive nature of limestone accelerates wear on crusher components. متكرر, lengthy shutdowns to replace liners, المطارق, or jaws halt your entire production line, costing thousands per hour in lost output.
عدم اتساق جودة المنتج: Fluctuations in feed size or moisture content can lead to offspec product from your primary crusher, causing bottlenecks and recrushing in secondary stages, reducing overall system yield.
Rigidity to Feed Variations: Many primary crushers struggle with slabby material or occasional oversize rock from the blast face, leading to blockages that require dangerous manual clearing and further downtime.
What if your primary crushing station could deliver more predictable operating costs, extend intervals between maintenance, and produce a more consistent feed for your downstream circuits?
2. نظرة عامة على المنتج
ال [Your Company Name] كسارة الصدم الأولية is engineered as a heavyduty, rotorbased machine for highvolume reduction of quarried limestone. It is designed to accept large feed rock (up to 60”) from the face and reduce it to a conveyable size for secondary processing in a single stage.
سير العمل التشغيلي:
1. Quarryrun limestone is fed via dump truck or wheel loader into the crusher’s large feed opening.
2. Material enters the robust rotor assembly, where massive hammers or blow bars accelerate it against stationary anvils or breaker plates.
3. Repeated impact fractures the rock along its natural cleavage planes.
4. Crushed material exits through an adjustable grate or apron setting, which controls the top product size.
5. Product is discharged onto a conveyor belt for transport to the next stage of processing.
نطاق التطبيق & القيود:
مثالية ل: Hightonnage quarry primary crushing of lowabrasive to moderately abrasive limestone; operations requiring high reduction ratios (ما يصل الى 20:1) في تمريرة واحدة; handling material with occasional clay or moisture content.
القيود: Not recommended for highly abrasive silicarich stone or granite as primary wear costs may become prohibitive. Requires consistent feed control for optimal performance and longevity.
3. الميزات الأساسية
نظام التعديل الهيدروليكي | الأساس الفني: أسطوانات هيدروليكية يتم التحكم فيها بواسطة الكمبيوتر | المنفعة التشغيلية: Allows operators to adjust the crusher gap setting (CSS) or open the housing for clearing in minutes from a remote location, without manual labor. | تأثير عائد الاستثمار: Reduces adjustment and clearing downtime by up to 80%, increasing annual operational availability.
MonoBody Rotor Design | الأساس الفني: Solid steel rotor disc with weldedon locking pieces for blow bars | المنفعة التشغيلية: Provides exceptional inertia for crushing large slabs and high mass throw for better reduction. Eliminates stress points found in segmented rotors. | تأثير عائد الاستثمار: تظهر البيانات الميدانية أ 3040% increase in service life over multipiece rotors under similar conditions, deferring major capital rebuild costs.
نظام أجزاء التآكل السريع | الأساس الفني: Wedgelocked blow bars and breaker plates with accessible tooling points | المنفعة التشغيلية: Your maintenance crew can reverse or replace all wear parts from outside the crusher using standard tools, significantly reducing liner changeout time. | تأثير عائد الاستثمار: Cuts planned maintenance windows by over 50%, translating directly into hundreds of additional production hours annually.
HeavyDuty Apron Feeder & Scalper Option | الأساس الفني: Integrated vibrating grizzly feeder (فجفف فجفف) with independent drive | المنفعة التشغيلية: Removes fines (6”) from the crusher feed prior to entry, reducing unnecessary wear and power consumption while boosting capacity on sticky material.| تأثير عائد الاستثمار: Improves overall system throughput by 1525% while lowering specific energy consumption (كيلوواط ساعة/طن).
Advanced Drive & Belt Guard System | الأساس الفني: Direct Vbelt drive from highefficiency TEFC motors with fully enclosed guards| المنفعة التشغيلية: Maximizes power transmission efficiency (>96%) while ensuring operator safety and compliance with MSHA/OSHA regulations.| تأثير عائد الاستثمار: Reduces energy loss compared to indirect drives; eliminates risk of costly violations and injuryrelated stoppages.
4. المزايا التنافسية
| مقياس الأداء | معيار الصناعة (Jaw/Gyratory) | Our Primary Impact Crusher Solution | ميزة (% تحسين) |
| : | : | : | : |
| Reduction Ratio (Single Pass) | 6:1 8:1 (فك), 5:1 8:1 (الدوران) | حتى 20:1 | +150% vs Jaw |
| ارتداء وقت التغيير الجزئي| 1624 ساعات (Jaw dies) / 48+ hrs (Gyratory concaves) | <8 ساعات (full set blow bars) | حتى 67% أسرع |
| Tolerance for Clay & رُطُوبَة| Low High risk of packing & choking| High Open discharge design handles moderate moisture without clogging| Significant operational flexibility |
| استهلاك الطاقة المحددة| خط الأساس (لعن الفك) | حتى 15% lower kWh/ton on comparable limestone| Direct reduction in operating cost |
| ضوضاء & توليد الغبار| High mechanical noise & dust at nip point| Lower mechanical noise; optional integrated water spray system available| Improved worksite environment |
5. المواصفات الفنية
تسمية النموذج: PI1615
نطاق السعة: 500 900 الهيدروكربونات النفطية في الساعة (dependent on feed gradation and product size)
فتح الأعلاف: 72” x 60” (1830mm x1520mm)
الحد الأقصى لحجم التغذية: Up to 60” (1524مم) cube
Rotor Diameter x Width:63” x60” (1600mm x1515mm)
متطلبات طاقة المحرك:600 HP(450 كيلوواط), TEFC electric motor
Approximate Operating Weight:120,000 lbs(54,400 كجم)
Key Wear Parts Material: Martensitic Chrome Steel Blow Bars; Manganese Steel Breaker Plates
نطاق التشغيل البيئي: Ambient temperatures from 20°Fto +120°F(29°Cto +49°C); dustand weatherprotected bearings.
6. سيناريوهات التطبيق
Midwest Aggregate Producer – HighSilica Limestone Quarry
تحدي: A major producer faced excessive wear on jaw crusher manganese dies every 6 weeks due to high quartz content in their limestone seam, causing recurring downtime and unpredictable cost spikes.
حل: Implementation of our Primary Impact Crusher configured with specialized highchrome martensitic blow bars designed for abrasion resistance.
نتائج: Wear life extended to an average of14 weeksbetween changes—a133% improvement.Downtime events were cut by more than half,and consumable costperton was reduced by28%.
Integrated Cement Plant – Direct Feed to Raw Mill
تحدي: The plant’s old gyratory crusher could not handle variations in quarry moisture without frequent bridging.The resulting inconsistent feed size disrupted raw mill optimization.
حل: A turnkey installation replacing the gyratory with our Primary Impact Crusher equipped with an integral apron scalper.
نتائج: The scalper removed problematic fines,and the impactor’s open design eliminated bridging.Product consistency improved,variationin raw mill feed size was reduced by70%,andmill throughput increased by12%.
Large Road Base Producer – SinglePass Crushing
تحدي: Producing specification road base required primary و secondary crushing stages,increasing capital footprint,fuel costs,and manpower.
حل: Deployment of a largecapacity Primary Impact Crusher set with a closedside apertureto produce a wellgraded0”4”productin one pass.
نتائج:The twostage circuit was consolidated into one.Reduced equipment count lowered fuel consumption by22%,and labor requirements were streamlined,increasing net profit per tonby18%.
الاعتبارات التجارية
Our Primary Impact Crushers are offered across three capability tiers:
1.مستوى الواجب القياسي(Models PI1010toPI1313): For lower tonnage (<400الهيدروكربونات النفطية في الساعة) operations.Pricing typically rangesfrom$250K$450K USD.Base configuration includes standard rotor,civil drawing package,والضوابط الأساسية.
2.HeavyDuty Tier(Models PI1415toPI1620): For mainstream quarry applications(400-1000 طن في الساعة).Pricing typically rangesfrom$500K$900K USD.Includes features like hydraulic adjustment,martensitic starter blow bar set,and advanced bearing monitoring.
3.Modular Plant Tier(Fully SkidMounted Systems): Includescrusher,VGFfeeder,takeaway conveyor,and walkways.Pricing starts at$1.M USD.Designedfor rapid deploymentwith minimal civil works.
تشمل الميزات الاختيارية:
Automated Gap Control(AGC)نظام
Thirdgeneration composite ceramicwear linersfor ultraabrasive applications
Dust suppression/waterspray ring package
حزمة التحكم عن بعد للمراقبة عن بعد
We offer comprehensive service agreements covering scheduled maintenance,inspections,andwear part supply at predictable fixed rates.Financing options includeoperating leases,capital leases,and projectspecific financing through our partners,directly aligning payment scheduleswith your production cash flow.
التعليمات
س:What downstream equipment is this crusher compatible with?
أ:The Primary Impact Crusherexcels at creatinga wellfractured,cubical product idealfor feeding cone crushersor horizontal shaft impactorsin secondary positions.It integrateswith all standard conveyingand screening systems.
س:What is therealistic expectedwear part lifein hard limestone?
أ:Lifedepends on abrasiveness(free silica content).Industry testing demonstratesblow bar life rangingfrom80，000to200，000tonsin typical commercial limestonematerial.Specific projectionsare provided during application review.
س:Canyou handlethe oversizefromour blasting which sometimesexceedsyour statedmax feedsize?
أ:The robustrotorandhydraulic opening systemare designedto handle occasional oversize.The keyis properfeed controlatthe face.We recommend pairingthecrusherwithour optionalheavyduty apron feederfor best resultsin such conditions.
س:What arethe lead timesfor majorwear components?
أ：We maintainstrategic stockof commonblow barandbreaker plate setsfor our HeavyDuty tier modelsin regional warehouses，targetingshipmentwithin72hoursfor emergency ordersunder service agreements。
س：How doestheoperatingcostcomparetoajawcrusheroverfiveyears？
أ：TotalCostofOwnership(TCO）analysesconsistentlyshowalowerTCOforthePrimaryImpactCrusherafieryearsdespitehigherinitialwearpartcost。Thesavingsarederivedfromlowerenergyconsumption（－15％），reduceddowntime（－40％），andhigheryieldofinspecproduct。ArepresentativeTCOmodelforyouroperationcanbeprovided。
س：Whatlevelof foundationisrequired？
أ：Asastandalonemachine，itrequiresasubstantialreinforcedconcretefoundation。Ourengineeringpackageincludesfullloaddynamicfoundationdrawingsforyourcivilcontractor。Themodularskid－mountedplantoptiondrasticallyreducesthiscivilrequirement。
س：Areoperator trainingandsupport included？
أ：نعم。Purchaseincludesacomprehensiveonsite trainingprogramforyouroperatorsandmaintenanceteamon safeoperation，dailychecks，andbasic troubleshooting。بالإضافة إلى ذلك，24／7technicalphone supportisprovided。