ورقة بيانات شركات معدات تكسير الصابورة للمحجر
1. فتحة مدفوعة بنقطة الألم
Are you managing a quarry ballast operation where inconsistent product gradation, توليد الغرامات المفرطة, and unplanned maintenance are eroding your margins? The primary challenges in producing highspecification railway ballast and construction aggregate are clear:
Gradation Inconsistency: Failure to consistently meet the strict particle size distribution (PSD) for railway ballast (على سبيل المثال, أريما, في 13450) leads to product rejection, إعادة السحق, والإيرادات المفقودة.
ملابس عالية & تكاليف التوقف: الطبيعة الكاشطة للجرانيت, البازلت, and limestone rapidly degrades crusher liners and impact elements, causing frequent stoppages for component replacement and escalating your costpertonne.
توليد الغرامات المفرطة: Improper crushing action creates an overabundance of 10mm material, which is waste in ballast production. This reduces your yield of premium, فحص المنتج.
كثافة الطاقة: Inefficient crushing chambers and drive systems result in high power consumption per tonne of final product, مما يؤثر بشكل مباشر على النفقات التشغيلية.
Plant Inflexibility: Fixedconfiguration crushers cannot adapt to varying feed material hardness or changing product specification demands without significant downtime for reconfiguration.
How do you increase the yield of premium quarry ballast while controlling wear costs and ensuring plant uptime? The answer lies in selecting purposeengineered quarry ballast crushing equipment.
2. نظرة عامة على المنتج
This datasheet details our range of stationary and mobile primary jaw crushers and secondary cone crushers engineered specifically for highvolume quarry ballast production. These machines are designed to transform blasted rock into precisely graded, مجموع مكعب.
سير العمل التشغيلي:
1. التخفيض الأولي: Blasted feed (typically 750mm) is introduced into a heavyduty jaw crusher. The deep crushing chamber and aggressive nip angle facilitate initial size reduction to a manageable 250mm product.
2. ثانوي & سحق الثلاثي: The primary crushed material is then fed into a cone crusher operating in a closed circuit with a sizing screen. This stage is critical for achieving the final cubical shape and exact gradation.
3. التحجيم & إعادة التدوير: Oversize material from the screening deck is recirculated back to the cone crusher (عملية الدائرة المغلقة), while inspec quarry ballast is conveyed to stockpile.
نطاق التطبيق & القيود:
نِطَاق: Ideal for medium to hard abrasive rock (الجرانيت, البازلت, الكوارتزيت). Suitable for both largescale stationary quarries and mobile contract crushing setups requiring relocation.
القيود: Not designed for very soft or nonabrasive rock (على سبيل المثال, chalk), where alternative crusher types may be more appropriate. Maximum feed size is determined by the specific primary crusher model selected.
3. الميزات الأساسية
تعديل Hydroset CSS | الأساس الفني: Hydraulic piston adjusts the closedside setting (CSS) تحت الحمل | المنفعة التشغيلية: Allows operators to finetune product gradation in minutes without stopping the crusher, responding to realtime feed changes | تأثير عائد الاستثمار: Eliminates production downtime for mechanical shim adjustments, increasing annual throughput by up to 7%
Liner Wear Compensation | الأساس الفني: Automated system maintains CSS via hydraulic positioning as liners wear | المنفعة التشغيلية: Delivers consistent product gradation over the full liner life without manual intervention | تأثير عائد الاستثمار: Maintains premium product yield and reduces risk of offspec production by an average of 15%
MultiAction Crushing Chamber | الأساس الفني: Optimized chamber geometry combines attrition, compression, and interparticle crushing | المنفعة التشغيلية: Promotes grainongrain breakage for superior particle shape with lower fines generation | تأثير عائد الاستثمار: Increases saleable quarry ballast yield by 812% مقارنة بالغرف القياسية
تحمل الثقيلة & تصميم الإطار الرئيسي | الأساس الفني: Forged alloy steel mainframe with oversized spherical roller bearings | المنفعة التشغيلية: Sustains high shock loads from uncrushable material and ensures longterm structural integrity | تأثير عائد الاستثمار: Extends major component service life beyond 20,000 ساعات, reducing total cost of ownership
نظام التشغيل الآلي المعتمد على PLC | الأساس الفني: Programmable Logic Controller with loadandlevel sensors for chokefed operation | المنفعة التشغيلية: يحافظ على مستوى التجويف الأمثل تلقائيًا, maximizing throughput and protecting the crusher from damage | تأثير عائد الاستثمار: Optimizes power draw efficiency by up to 10% and prevents costly overload events
تصميم صديق للخدمة | الأساس الفني: Hydraulic tools for backing compound removal and topserviceable liner change design | المنفعة التشغيلية: Reduces liner changeout time by over 50% compared to traditional bolton designs | تأثير عائد الاستثمار: يقلل من تكاليف العمالة لكل حدث صيانة ويزيد من توافر المصنع
4. المزايا التنافسية
| مقياس الأداء | معيار الصناعة القياسي | الميزة الموثقة لحلول تكسير صابورة المحاجر لدينا |
| : | : | : |
| عائد المنتج (+22mm 63mm) | ~6570% of feed mass typically within spec range based on industry averages >75% consistently achieved through optimized chamber design >75% consistently achieved through optimized chamber design |
| حياة الخطوط الملاحية المنتظمة (المخروط الثانوي) ~500700 operating hours in abrasive granite >850 operating hours demonstrated in field trials >850 operating hours demonstrated in field trials |
| Energy Consumption ~0.8 1.1 kWh/tonne for secondary crushing ~0.65 0.9 kWh/tonne measured at multiple sites ~0.65 0.9 kWh/tonne measured at multiple sites |
| Gradation Consistency Standard deviation of ±8% on key sieve sizes Standard deviation tightened to ±4% via automation Standard deviation tightened to ±4% via automation |
5. المواصفات الفنية
نطاق السعة: من 200 طن في الساعة (mobile configurations) لأكثر من 1,200 tph (stationary primary/secondary plants).
متطلبات الطاقة: Primary jaw units from 110400 كيلوواط; Secondary cone units from 132315 كيلوواط. All drives compatible with VSDs for soft start capability.
مواصفات المواد: Designed for unconfined compressive strength (يو سي إس) ما يصل الى 350 MPa. Crusher wear parts manufactured from Mn18Cr2 or equivalent highgrade manganese steel.
الأبعاد المادية (مثال على مصنع متنقل): طول: ~19m; عرض: ~3m; ارتفاع: ~ 4 م; الوزن التشغيلي: ~48 tonnes.
نطاق التشغيل البيئي: Standard units rated for 20°C to +40°C ambient temperature. Dust suppression system connections standard on all models.
6. سيناريوهات التطبيق
Railway Ballast Production Plant Challenge A national rail infrastructure contractor faced recurring penalties due to flaky particle content exceeding network standards from their existing cone crushers Solution Implementation of a tertiary cone crusher with a multiaction chamber specifically tuned for cubicity Results Particle elongation index (EI) reduced from 28% to below 15%, ensuring full compliance AREMA 4A spec Firstyear yield increased by approximately €180k due reduced waste fines
Granite Quarry Expansion Challenge A large granite quarry needed higher throughput without expanding their primary circuit footprint or increasing energy costs Solution Replacement of two older secondary crushers with a single highcapacity cone model featuring advanced automation Results Throughput increased by 22% while specific energy consumption fell by18%. Payback period on equipment was achieved within14 months through increased sales volume
Contract Crushing Operator Challenge A mobile crushing contractor required rapid setup teardown between sites while maintaining precise output gradations across varying geology Solution Deployment trackmounted jaw cone plant featuring hydraulic setting adjustment quick release conveyor systems Results Site mobilization time reduced by40%. Operators can recalibrate CSS hydraulically between sites ensuring spec compliance across different projects without downtime
7 الاعتبارات التجارية
يتم تقديم معدات تكسير صابورة المحاجر الخاصة بنا عبر عدة مستويات:
التكوين القياسي: A costeffective package including core machine basic automation dust suppression
حزمة التوفر العالي: Includes upgraded wear monitoring telemetry extended warranty on major components
Turnkey Plant Design Engineering services site layout optimization integration with existing conveyors screens
Optional features include advanced rock level sensors automatic lubrication systems remote monitoring portals Service packages range from scheduled maintenance plans comprehensive life cycle contracts Financing options include capital purchase finance leases operational leases structured align payments project cash flow
8 التعليمات
What if my feed material hardness varies significantly throughout the quarry face?
The hydroset system allows quick CSS adjustment compensate variations Automation maintains choke feed ensuring consistent performance shape across different strata
How does this equipment integrate with my existing screening washing circuits?
Crushers are designed standard discharge heights conveyor widths Interface points clearly defined Our engineering team can provide integration drawings ensure compatibility
What typical operational training required for my team?
We provide comprehensive onsite training covering operation basic troubleshooting liner changes Most crews proficient within three five working days
Are wear parts readily available what expected lead times?
We maintain regional inventory critical wear parts Average lead time consumables like mantles concaves is under72 hours supported service network
What financing structures available beyond outright purchase?
We offer several models including3660 month finance leases which may offer tax benefits well as rental purchase agreements tailored seasonal cash flows