1. PAINPOINT DRIVEN OPENING

Managing a limestone quarry or processing plant presents distinct operational challenges that directly impact your bottom line. Are you contending with:
Excessive Downtime for Primary Crusher Maintenance: Frequent liner changes and unplanned stops in your primary crushing stage create bottlenecks, halting downstream processing and costing thousands per hour in lost production.
High Wear Part Costs in Secondary Crushing: The abrasive nature of limestone rapidly degrades crusher components, leading to unsustainable expenditure on replacement hammers, rotors, and liners.
Inconsistent Feed Size to Final Grinding/Pulverizing Circuits: Fluctuations in crusher discharge size reduce the efficiency of your final milling stages, increasing specific energy consumption (kWh/ton) and compromising product uniformity.
High Energy Consumption per Ton Processed: Outdated or improperly sized crushing circuits draw excessive power without delivering proportional throughput, eroding profit margins.
Dust Emission Control at Transfer Points: Unmanaged dust from crushing and screening not only creates environmental and health compliance issues but also represents significant product loss.

The central question is: how can you achieve higher throughput with lower operating costs while ensuring system reliability? The solution begins with optimizing the heart of your size reduction circuit.

2. PRODUCT OVERVIEW: LIMESTONE IMPACT CRUSHER

This equipment is a heavyduty, horizontal shaft impact crusher (HSI) engineered specifically for the primary and secondary crushing of limestone, dolomite, and other mediumhard aggregates. It transforms large quarryrun limestone into precisely graded aggregates or optimal feed for raw mills.

Operational Workflow:
1. Feed Intake: Quarryrun limestone (up to 800mm) is fed into the robust rotor assembly via a reinforced feed hopper.
2. HighVelocity Impact: The rotor hurls material against massive, adjustable impact aprons, utilizing kinetic energy to fracture the stone along natural cleavage planes.
3. Size Control & Recirculation: Crushed material passes through an adjustable gap between the aprons and rotor. Oversize material is recirculated for further impact, ensuring firstpass reduction efficiency.
4. Product Discharge: Correctly sized material exits the crusher chamber onto a conveyor for transport to downstream screening or stockpiling.

Application Scope & Limitations:
Ideal For: Primary or secondary reduction of blastquarried limestone (compressive strength < 150 MPa), producing cubical aggregate for construction or sized feed for cement raw mills.
Not Recommended For: Processing highly abrasive materials like granite or quartzite without significant configuration changes, or for ultrafine grinding applications below 5mm without closedcircuit screening.

3. CORE FEATURES

Hydraulic Adjustment System | Technical Basis: Computercontrolled hydraulic cylinders | Operational Benefit: Allows remote adjustment of the apron gap during operation to finetune product size or clear blockages in minutes | ROI Impact: Reduces downtime for size changes by up to 80% compared to manual shim systems

MonoBody Rotor Design | Technical Basis: Solid cast steel rotor disc with welded wear protection | Operational Benefit: Provides exceptional inertia for high reduction ratios and withstands shock loads from uncrushables; reversible upper/lower wear parts double service life | ROI Impact: Lowers lifetime rotor maintenance costs by an estimated 40% and increases operational availability

QuickChange Wear Part Cartridges | Technical Basis: Modular apron holder and hammer assemblies | Operational Benefit: Enables replacement of major wear components as preassembled units, reducing changeout time from shifts to hours | ROI Impact: Cuts labor costs per maintenance event by over 60% and limits production stoppage

Advanced Dust Management Integration | Technical Basis: Sealed housing with strategically placed extraction ports | Operational Benefit: Minimizes dust escape at impact zones; interfaces directly with your baghouse system to maintain cleaner site conditions | ROI Impact: Reduces product loss as airborne fines and lowers compliance risk

Direct Drive Transmission | Technical Basis: Fluid coupling connected directly to hightorque motor | Operational Benefit: Eliminates Vbelt maintenance, provides smooth startup under load, and transmits power more efficiently than indirect drives | ROI Impact: Improves energy efficiency by 35% over traditional beltdriven systems

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average HSI) | This Limestone Impact Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | ~8588% | >93% (documented) | +58% |
| Wear Cost per Ton (Secondary Crushing) $/ton | $0.45 $0.60 | $0.28 $0.35 (field data) | ~35% Reduction |
| Reduction Ratio (Limestone) Max / Avg. Feed Size Ratio| 15:1 18:1| Up to 20:1| +1015% |
| Energy Consumption kWh/tonne| 0.8 1.1 kWh/t| 0.65 0.85 kWh/t| ~20% Improvement |
| Mean Time Between Maintenance (Wear Parts)| 120 150 operating hours| 180 220 operating hours| +4050% |

5. TECHNICAL SPECIFICATIONS

Model Designation: HSILS6565
Capacity Range: 400 – 650 tonnes per hour (dependent on feed size and product gradation)
Rotor Diameter & Width: Ø1650 mm x 2100 mm
Drive Power Requirement: 500 – 630 kW electric motor
Max Feed Size: Edge length up to 800 mm
Weight (Crusher Only): Approximately 58 metric tons
Housing Material: Hardox 450 steel plate at critical wear points
Rotor Inertia Class: Heavyduty design exceeding 25 kgm²
Operating Temperature Range: 20°C to +45°C with standard lubrication
Noise Emission Level at 10m Distance: < 85 dB(A)

6. APPLICATION SCENARIOS

Cement Raw Material Preparation Plant Challenge:

A major cement producer faced inconsistent feed size (<100mm variance) from their primary gyratory crusher to their raw mill, causing power spikes and reduced mill output.

Solution:

Installation of an HSILS model as a secondary crusher in closed circuit with a screen.

Results:

Product PSD stabilized within a ±25mm range; raw mill throughput increased by 12%, with specific energy consumption decreasing by 8%. Payback period was achieved in under 14 months through energy savings alone.

HighQuality Aggregate Quarry Challenge:

An aggregate supplier needed a more cubical product for asphalt chips but was using a cone crusher that produced excessive flaky material, limiting premium product yield.

Solution:

Replacement of tertiary cone stage with a configured limestone impact crusher focused on shaping.

Results:

Cubicity index improved from 68% to 87%, allowing a 30% increase in sales of premiumpriced chip products while simultaneously reducing wear costs from the previous cone crusher mantle/liner changes.

7. COMMERCIAL CONSIDERATIONS

Our limestone impact crushers are offered under three primary configurations:

1. Standard Production Model includes core features listed above.
2.HighAvailability Package adds condition monitoring sensors (vibration, temperature), automated lubrication system,
and spare wear part cartridges.
3.Turnkey Mobile/SkidMount Option includes integrated feeder,
prescreen,and walkways on a single chassis for rapid deployment.

Service packages range from basic technical support
to comprehensive annual maintenance contracts including scheduled inspections,
wear part inventory management,and priority field service response.Financing options include capital purchase,
operational lease,and throughputbased agreements structured over 3660 months.Please inquire for detailed quotations based on your specific production targets.

8.FAQ

Q:What existing foundation work is required?
A:The crusher requires a reinforced concrete foundation designed to handle dynamic loads.Specific civil engineering drawings are provided upon order.

Q.Can this crusher handle occasional tramp metal?
A.The robust rotor design includes overload protection,but it is not a substitute for proper upstream magnetic separation.Auxiliary tramp iron relief systems are available as an option.

Q.How does it integrate with our existing PLC/control system?
A.The unit comes standard with local control but includes industrystandard communication protocols(Profibus,Ethernet/IP)
for seamless integration into your plantwide SCADA system for monitoring key parameters like power drawand bearing temperature

Q.What is the typical lead time from order commissioning?
A.For standard models lead time is 1620 weeks.Fasttrack options may be available subjectto component inventory

Q.Are performance guarantees offered?
A Yes we provide guaranteed minimum throughput capacityand maximum wear cost per ton based on agreedupon feedmaterial analysis