1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing unpredictable production bottlenecks and rising operational costs in your aggregate or mineral processing plant? Key challenges with secondary and tertiary crushing often include:

Coûts élevés des pièces d’usure & Temps d'arrêt imprévus: Remplacement fréquent des marteaux, doublures, and blow bars due to abrasive materials, leading to significant parts expenditure and production halts.
Gradation du produit incohérente: Fluctuations in feed material density or composition can cause unwanted fines or oversized product, failing to meet strict specification requirements for downstream processes or final product sales.
Consommation d'énergie excessive: Older or inefficient impact crusher designs consume disproportionate power per ton of processed material, directly impacting your bottomline operating costs.
Flexibilité d'application limitée: A crusher that cannot be adjusted efficiently for different product sizes or material types forces operational compromises and limits plant versatility.

Is there a solution that delivers consistent product shape, reduces total cost of ownership through superior wear management, and provides the operational flexibility modern operations demand?

2. APERÇU DU PRODUIT: HIGHPERFORMANCE EXPORT IMPACT CRUSHERS

Our line of exportready horizontal shaft impact (HSI) crushers is engineered for highvolume reduction of medium to lowabrasive materials such as limestone, béton recyclé, asphalte, et débris de démolition. These machines are central to aggregate production and recycling operations.

Flux de travail opérationnel:
1. Entrée de flux: Material is directed into the robust feed hopper and onto the adjustable feed chute.
2. Accélération & Impact: Material is struck by highvelocity rotating hammers (barres de soufflage) mounted on a solid rotor assembly and hurled against the adjustable primary impact aprons (rideaux).
3. Controlled Reduction: Size reduction occurs through both initial impact and subsequent collisions between particles (rockonrock crushing within the chamber).
4. Éjection du produit & Dimensionnement: Crushed material exits through the adjustable gap between the rotor and the aprons. A secondary apron/cage may be used for further refinement before discharge onto a conveyor.

Champ d'application & Limites:
Idéal pour: Calcaire, dolomie, béton/asphalte recyclé (RAP/RAS), sable & gravier, charbon, and similar materials with low to medium silica content.
Limites: Non recommandé pour les matériaux très abrasifs (par ex., granit, piège à pierres, quartzite) as primary reduction units due to accelerated wear rates; these are better served by primary jaw or cone crushers.

3. CARACTÉRISTIQUES PRINCIPALES

Système de réglage hydraulique | Base technique: Vérins hydrauliques commandés par ordinateur | Avantage opérationnel: Allows operators to adjust the primary apron setting during operation for realtime product size control without stopping production. | Impact sur le retour sur investissement: Réduit les temps d’arrêt des réglages jusqu’à 90%, increasing annual throughput capacity.

Conception modulaire des composants d'usure | Base technique: Segmented wear plates and reversible/rotatable blow bars | Avantage opérationnel: Enables partial replacement of worn sections and extends component life by utilizing multiple edges. Reduces maintenance time through simpler handling. | Impact sur le retour sur investissement: Réduit les coûts d’inventaire des pièces d’usure de 2540% and reduces labor hours per changeout by an estimated 30%.

Solid Rotor vs. Open Disc Design | Base technique: Fabricated steel rotor with monolithic structure | Avantage opérationnel: Provides superior inertia for crushing larger feed sizes and higher durability with fewer stress points compared to open disc rotors. Essential for heavyduty applications. | Impact sur le retour sur investissement: Augmente le temps moyen entre les pannes (MTBF) for the rotor assembly, reducing major overhaul frequency and associated capital repair costs.

Géométrie de chambre avancée | Base technique: Optimized internal profiles derived from computational fluid dynamics (CFD) analyse | Avantage opérationnel: Improves material flow through the crushing chamber, reducing recirculation load and power surges while enhancing particleonparticle breakage for better cubicity. | Impact sur le retour sur investissement: Atteint jusqu'à un 15% amélioration de l'efficacité énergétique (kWh/tonne) compared to previousgeneration designs.

Portes de maintenance QuickAccess | Base technique: Grand, hinged service doors with safety lockout provisions | Avantage opérationnel: Fournit un coffre-fort, direct access to the interior chamber for inspection, blow bar rotation/replacement, and apron adjustment without major disassembly. | Impact sur le retour sur investissement: Cuts standard service intervals from hours to minutes directly translating to higher plant availability.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Our Export Impact Crusher Solution | Avantage documenté |
| : | : | : | : |
| Coût d'usure par tonne (Calcaire) | $0.022 $0.035/tonne | $0.016 $0.025/tonne | Jusqu'à 30% Réduction |
| Consommation d'énergie (kW par 100 tph) ~250 kW / 100tph ~215 kW / 100tph ~14% Improvement in Efficiency |
| Indice de cubique du produit (>20fraction en mm) CI of 0.75 0.85 CI consistently >0 .88 Improved Aggregate Shape |
| Average Time for Apron Gap Adjustment Manual shim adjustment (~48 hrs) Système hydraulique (~2030 mins) ~90% Faster Adjustment |

5.SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Modèles disponibles chez 150 à 800+ tonnes par heure (TPH), depending on feed material density and product size setting.
Diamètre du rotor & Largeur: From Ø1300mm x 1200mm up to Ø2000mm x 2500mm configurations.
Drive Power Options: Entraînements par moteur électrique allant de 250 kW à 800 kW , tailored to regional voltage standards (e.g.,50Hz /60Hz ,400V ,6 .6kV).
Taille de l'ouverture d'alimentation: Up t o1600mm x2500 mm maximum feed size capability .
Spécifications des matériaux clés :
Arbre de rotor :Forged42CrMo steel ,testé par ultrasons .
Logement : Fabricatedfromhigh yieldstrengthsteelplatewithinternalbolt onwearliners .
Barres de soufflage : Premium chromium ceramic composite alloys or martensitic steel options available .
Plage de température de fonctionnement : Designedforambientoperationfrom20°Cto+45°Cwithappropriate lubrication systems .

6 .SCÉNARIOS D'APPLICATION

Aggregate Quarry Expansion Challenge A Midwest US limestone quarry needed t oincrease minus 1”baseproductproductionwithoutaddinganewcrushinglineorbudgetforfrequentdowntime .Solution Installationofahigh capacityexportimpactcrusherasasecondaryunitpost jawcrusher ,utilizingitshydraulicadjustmenttoshiftbetween1”and¾”productasneeded .Results Theplantachieveda22 %increaseinbaseproductthroughput .Wearcostsremainedstable despitehighertonnage ,andoperatorscouldmeetchangingdailyorderspecificationsinunderanhour .

Construction &Démolition(C&D )RecyclingFacility Challenge AnurbanC&Drecyclerfacedexcessivewearandunacceptablemetalliccontamination( barres d'armature )intheirfinalaggregateproductfromanolderimpactcrusher .Solution Implementationofasolid rotorexportimpactcrusherequippedwithspecializedblowbarsto handlehighshockloadsandembeddedmetal .Thedesignincludedamagneticseparationconveyorpost crush .Results Contaminationinminus ¾”recycledaggregatefellbelow1 %byweight ,meetingstrictspecificationsfordrainageapplications .Blowbarlifeincreasedbyapproximately60 %despitetheabrasiveandunpredictablefeed .

7.CONSIDÉRATIONS COMMERCIALES

Our export impact crushers are offered in three primary tiers :

Série de service standard : Forconsistent ,medium abrasivematerials(likepurelimestone ).Focusesoncore reliabilityandcapitalcostoptimization .
Série robuste : Fortougherapplicationsincludingrecycledconcretewithhighercontaminantlevels .Featuresreinforcedcomponentsandsolidrotortechnologyasstandard .
Modular Plant Series : Fullyintegratedskid mountedorsemi portableunitspre wiredandpipedforrapiddeployment ;includespresetfeedersandscreens .

Optional features include automatedgreasingsystems ,vibrationmonitoringpackages ,specializedwearlinermaterials( e.g.,ceramicinserts ),andenclosedwalkwaysforservice .

We offercomprehensiveservicepackagesfrombasiccommissioningtofullannualmaintenanceagreementswithguaranteedresponse times .Financingandleasingoptionsareavailablethroughpartnersto managedeploymentcapital .

8.FAQ

T1:Arewearpartsinterchangeablewithotherbrandsofcrushers ?
A1 No Ourexportimpactcrushersaredesignedwithproprietarymodularwearcomponentsforsuperiorperformanceandspecificbalancingrequirements Weguaranteeoptimalperformanceonlywithourgenuineparts

T2:Whatisthetypicalleadtimeforreplacementrotorsor majorshaftcomponents ?
A2 Forcriticalcomponentslikerotors we maintain strategic inventory of key sub assemblies Lead times vary but we target shipment of major components within46weekswithemergencysupportoptionsavailable

T3:Canyourimpactcrusherhandleaclosedcircuitoperationwithareturnfeed( recirculatingload)?
A3 Yes allmodelsaredesignedforthedemandsofclosedcircuitoperations Thesolidrotordesignprovidesthenecessaryinertiaandthehydraulicsystemallowsquickcompensationforchangesinchamberload

T4:Doyouprovideperformanceguarantees ?
A4 Yes weoffercontractualguaranteesforcapacity throughput basedonagreedfeedmaterialanalysis aswellasmaximumwearratesforblowbarsandlinersunderdefinedoperatingconditions

Q5:Quelle formation est dispensée à nos opérateurs et à notre personnel de maintenance ?
A5 Weincludecomprehensiveonsiteoperator trainingduringcommissioning coveringnormaloperation adjustmentsafetyprotocolsanddailychecks Indepthmaintenancetrainingfocusedonwearpartreplacementandsystemdiagnosticsisalsoavailable

Q6:Iscustomizationavailablefordifferentvoltageorpowersupplyrequirements ?
A6 Absolutely Asanexport specialist weengineereachunittomeetthedestinationcountry’sspecificpowerstandards includingmotors startersandcontrolpanelconfigurations

Q7 Howdoesthecostofownershipcomparetoaconecrusherforsimilarapplications ?
A7 Forlowto mediumabrasivematerials anexportimpactcrusheroffersalowerinitialcapitalinvestment significantlylowerwearcostspertonneproducesamorecubicalproduct butmayhavehigherwearcostsinhighlyabrasiveapplicationscomparedtoacone OurteamcanprovideadetailedTCOanalysisbasedonyourspecificmaterial