1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Êtes-vous confronté à des goulots d'étranglement persistants dans votre chaîne de production de ciment qui érodent la rentabilité? Pour les directeurs d’usine et les entrepreneurs en ingénierie, key operational challenges often center on core material handling and processing equipment. Inefficient or unreliable equipment for raw material preparation directly impacts your entire operation's throughput and bottom line.

Temps d'arrêt pour maintenance élevé: Fréquent, unplanned stoppages for repairs on crushers, mangeoires, or prehomogenization systems halt the kiln feed, costing thousands per hour in lost production and emergency labor.
Inconsistent Feed Quality: Fluctuations in raw mix chemistry due to inadequate blending or sizing lead to process instability in the kiln and mill, increasing specific heat consumption and compromising final cement quality.
Consommation d'énergie excessive: Outdated or improperly sized equipment operates far from its optimal efficiency point, drawing excess power for crushing, affûtage, and conveying—a major and controllable operational cost.
Dégradation rapide des pièces d’usure: Abrasive raw materials like limestone and shale can devastate equipment internals, leading to high spare part costs, frequent changeouts, and associated safety risks during maintenance.

La question centrale est: comment pouvez-vous obtenir des, precisionengineered equipment that delivers predictable performance, minimizes lifecycle cost, and ensures a consistent feed to your pyroprocessing line?

2. APERÇU DU PRODUIT: Raw Material Crusher & PreHomogenization Stacker/Reclaimer Systems

This product category encompasses the heavyduty machinery responsible for the primary size reduction and homogenization of raw materials (calcaire, argile, schiste argileux, etc.) in cement plant operations. The operational workflow is critical to downstream efficiency:

1. Concassage primaire: Runofmine material is reduced to a manageable size (typiquement <100mm) by primary crushers (par ex., jaw gyratory crushers).
2. PreHomogenization Stockpiling: Crushed material is systematically stacked in longitudinal layers using a stacker to create a blended stockpile.
3. Reclaiming: A bucketwheel reclaimer traverses the pile face, simultaneously cutting material from all layers to ensure a consistent chemical composition.
4. Concassage secondaire & Convoyage: Reclaimed material may undergo secondary crushing before being conveyed as a homogenized mix to the raw mill.

Champ d'application & Limites: Cet équipement est conçu pour des tonnages élevés, 24/7 cement raw material processing. It is not suitable for final cement grinding or handling highly corrosive substances without specific material adaptations. Optimal performance requires proper foundation engineering and integration with plantwide control systems.

3. CARACTÉRISTIQUES PRINCIPALES

Rotor robuste & Plaques d'impact | Base technique: Highchromium cast iron alloy with ceramic inserts | Avantage opérationnel: Exceptional resistance to abrasive wear from silica and alumina in raw mix | Impact sur le retour sur investissement: Jusqu'à 40% longer service life reduces part replacement frequency and inventory costs.

Protection hydropneumatique contre les fers clochards | Base technique: Automatic release and reset mechanism activated by uncrushable material | Avantage opérationnel: Prevents catastrophic damage to crusher main shaft and housing from tramp metal | Impact sur le retour sur investissement: Avoids days of downtime and sixfigure repair bills associated with major mechanical failure.

PLCIntegrated Stacker/Reclaimer Control | Base technique: Programmable Logic Controller managing slewing, travel, and bucketwheel speed | Avantage opérationnel: Enables precise chevron or windrow stacking and homogenized reclaiming for consistent feed chemistry | Impact sur le retour sur investissement: Reduces kiln feed variability by over 70%, lowering specific fuel consumption by an estimated 35%.

Graissage centralisé & Surveillance des conditions | Base technique: Système de lubrification automatisé avec capteurs de débit et ports d'analyse des vibrations | Avantage opérationnel: Garantit une santé optimale des roulements dans des conditions de charge élevée; permet la planification de maintenance prédictive | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements de 30%+ and converts unplanned stops into planned maintenance windows.

Conception modulaire des composants d'usure | Base technique: Segmented breaker plates and bolted liner sections | Avantage opérationnel: Allows for partial replacement of worn sections without full dismantling | Impact sur le retour sur investissement: Cuts scheduled maintenance downtime by half compared to singlepiece liner replacement.

Entraînement à fréquence variable (VFD) Moteurs de convoyeur | Base technique: AC motor drive controlling speed and torque electronically | Avantage opérationnel: Allows softstarting to reduce belt stress; enables speed matching to actual feed rate saving energy | Impact sur le retour sur investissement: Can reduce conveyor energy use by 1525% during nonpeak operation.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Our Crusher & S/R Solution Documented Advantage |
| : | : | : |
| Disponibilité (Temps de fonctionnement prévu) | 9294% >96% +24% amélioration |
| Consommation d'énergie spécifique (kWh/tonne) Varies by material ~510% reduction Field data shows consistent reduction through optimized drive trains & Contrôle VFD. |
| Temps moyen entre les pannes (MTBF) Key Components ~6 months >9 mois +50% extension Enhanced design & metallurgy increase component lifespan. |
| Homogenization Effect (Standard Deviation Reduction) 1:8 à 1:10 rapport >1:15 ratio Superior blending Provides tighter kiln feed control for more stable burning zone conditions. |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Primary Crushers from 800 TPH à 2,500 TPH; Stacker/Reclaimers from 500 TPH à 1,800 TPH.
Exigences d'alimentation: Puissances moteur de 200 kW jusqu'à 1,200 kW par unité; supplied for voltages of 6kV or lower as per plant infrastructure.
Spécifications matérielles: Mainframe construction in heavyweld steel plate (Q345B/St52). Critical wear parts in Mn Steel (ZGMn13), HighChromium Iron (Cr26), or composite ceramicmetal alloys.
Dimensions physiques: Highly projectspecific; primary crusher foundations typically require >150m³ of reinforced concrete.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; coffrets électriques antipoussière (IP65); components rated for outdoor operation under standard industrial atmospheric conditions.

6. SCÉNARIOS D'APPLICATION

Greenfield Plant Project in Southeast Asia

Challenge A new integrated cement plant required a complete raw milling circuit capable of processing highly abrasive limestone with minimal future operational risk.
Solution Supply of a primary jaw gyratory crusher suite paired with a portal scraper reclaimer system for prehomogenization.
Results The plant achieved nameplate capacity within two months of commissioning. The homogenization system delivered a kiln feed variance below ±0.2% CaO, contributing directly to an annual calculated fuel saving of approximately $280,000.

Capacity Expansion at Mature North American Plant

Challenge An existing plant’s bottleneck was its aging singlestage impact crusher causing inconsistent sizing and excessive downtime (>15 jours/an).
Solution Retrofit installation of a twostage crushing circuit with an intermediate screen deck controlled by an upgraded PLC system.
Résultats Débit augmenté de 22%. Product sizing met raw mill specifications over 99% du temps. Annual maintenance hours related to the crushing circuit decreased by an estimated 35%.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Equipment cost scales primarily with capacity (TPH) rating level:
Service standard (1800 TPH): With premium metallurgy features for severe service.
Fonctionnalités facultatives: Advanced online condition monitoring packages remote diagnostic access automated fire suppression systems dust suppression nozzle kits special corrosionresistant coatings
Forfaits de services: Extended warranty plans annual inspection contracts bulk spare part agreements onsite technician training programs
Financing Options Available through partners include capital lease operating lease project financing structures tailored major capital expenditure

8.FAQ

Q What information is needed confirm technical compatibility my existing plant layout?
A We require your existing foundation drawings conveyor interface details electrical supply point specifications current feedstock analysis maximum incoming lump size

Q How does implementation typically affect ongoing operations?
A Greenfield projects follow new construction timeline Retrofit projects are planned around scheduled kiln shutdowns with modular designs minimize installation time often between weeks

Q What measurable impact can expect my overall plant efficiency?
A Field data from similar installations shows reductions specific energy consumption raw preparation section between improvements product consistency translate lower thermal consumption kiln

Q Are spare parts readily available what lead times expected?
A Critical wear parts common consumables held regional warehouse stock Standard lead times nonstock items are communicated realtime our inventory system

Q What commercial terms standard large capital equipment orders?
A Typically involve progress payments tied manufacturing milestones FOB Incoterms Performance guarantees cover capacity power consumption availability

Q Do you provide supervision installation commissioning?
A Yes we offer comprehensive technical advisory services optional fullscope erection commissioning managed our field engineers

Q Can equipment be integrated with existing distributed control system DCS
A All our PLCbased controls are designed standard communication protocols Modbus OPC UA ensuring straightforward integration major DCS platforms