HPA4000 HeavyDuty Hammer Mill | Engineered for Uninterrupted Mineral Reduction

1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L’augmentation des coûts opérationnels et les temps d’arrêt imprévus érodent vos marges de traitement des minéraux? Plant managers and engineering contractors consistently face three critical challenges in size reduction operations:

Temps d'arrêt excessif pour la maintenance: Frequent wear part replacement halts your entire crushing circuit. Industry data indicates that standard hammer mills can require liner and hammer changes every 400600 hours in abrasive applications, coûtant plus 50 hours of annual production time per unit.
Gradation de sortie incohérente: Fluctuations in feed material hardness or moisture content lead to an offspec product, causing bottlenecks in downstream processes and potential rejections.
Unscheduled Bearing Failures: Contamination ingress and imbalanced rotor assemblies cause catastrophic bearing failures, resulting in repair costs exceeding $15,000 and multiday production stoppages.

Comment obtenir un débit constant, réduire le coût total de possession, and protect your operation from costly interruptions? The solution requires a hammer mill engineered not just to process material, but to withstand the demands of continuous industrial service.

2. APERÇU DU PRODUIT

The HPA4000 is a heavyduty, industrial hammer mill designed for primary, secondaire, or tertiary reduction of mediumhard to hard minerals such as limestone, gypse, charbon, and phosphate rock. Its design prioritizes durability and controlled fragmentation for aggregate production, prétraitement minier, et préparation minérale industrielle.

Flux de travail opérationnel:
1. Alimentation contrôlée: Material is introduced via a regulated feed conveyor into the mill’s reinforced feed chute.
2. Réduction des impacts: A highinertia rotor assembly with dynamically balanced hammers accelerates material into the manganese steel breaker plates.
3. Classement des tailles: Processed material passes through a heavyduty grate screen; particles meeting spec exit, tandis que les matériaux surdimensionnés sont conservés pour une réduction supplémentaire.
4. Décharge & Transport: Sized material is discharged for conveyance to the next stage in your processing circuit.

Champ d'application & Limites:
Idéal pour: Mediumhard materials (jusqu'à 8 Mohs), dry or slightly moist feeds requiring top sizes from 50mm down to 3mm.
Non recommandé pour: Ultraabrasive materials like silica sand without specific liner configurations, highly sticky or claybound feeds without prescreening, or applications requiring submillimeter pulverization.

3. CARACTÉRISTIQUES PRINCIPALES

Système de rotor réversible | Base technique: Symmetrical rotor design with hardfaced hammer mounting points | Avantage opérationnel: When the leading edges of hammers wear, operators can reverse the rotor direction or flip hammers to utilize a second cutting edge without disassembly downtime | Impact sur le retour sur investissement: Doubles service intervals for hammer sets, reducing parts consumption by up to 40% annuellement.

Plaques de disjoncteur segmentées & Grates | Base technique: Individual highchrome cast alloy sections secured with captive bolts | Avantage opérationnel: Worn sections can be replaced individually in under two hours instead of replacing an entire liner assembly | Impact sur le retour sur investissement: Réduit les temps d'arrêt liés au remplacement du revêtement de 70% and reduces consumable inventory costs.

Sceau du labyrinthe & AirPurge Bearing System | Base technique: Multistage dust exclusion seals supported by a regulated air purge | Avantage opérationnel: Creates positive pressure to prevent abrasive dust ingress into main rotor bearings | Impact sur le retour sur investissement: Extends bearing service life by a documented minimum of 300%, eliminating unscheduled bearing failures.

Équilibrage dynamique & Coussinets de surveillance des vibrations | Base technique: Factorybalanced rotor with integrated sensor mounting points on the housing | Avantage opérationnel: Allows for routine vibration trend monitoring; enables predictive maintenance scheduling before imbalance causes damage | Impact sur le retour sur investissement: Prevents cascading component failures, protecting against an average of $25k in unexpected repair costs.

Portes de maintenance QuickAccess | Base technique: Hydraulicallyassisted side and top doors with integrated safety interlocks | Avantage opérationnel: Fournit un accès complet à la chambre de broyage pour inspection, changements d'écran, or cleanup in minutes without overhead crane dependency | Impact sur le retour sur investissement: Reduces standard maintenance window duration by over 60%, returning the mill to production faster.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Moy. du concurrent.) | HPA4000 Hammer Mill Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Durée de vie des pièces d'usure (Minerai abrasif) | 550 Heures d'ouverture | 850 Heures d'ouverture | +55% Durée de vie plus longue |
| Temps de travail pour le changement d'écran (2personne équipage) | 4.5 Heures | 1.75 Heures | 61% Less Downtime |
| Consommation d'énergie spécifique (kWh/tonne) Documenté| ~1.8 kWh/ton @ 10mm output| ~1.65 kWh/ton @ 10mm output| 8.3% Consommation d'énergie réduite |
| Annual Bearing Replacement Rate (24/7 Op.)| >1.0 per year per mill| <0.33 per year per mill| 67% Fewer Replacements |

5. SPÉCIFICATIONS TECHNIQUES

Capacité nominale: 120 180 TPH (dependent on feed material and target output size)
Exigences d'alimentation: Moteur d'entraînement principal: 400 kW (500 HP), WEG Premium Efficiency IE3
Assemblage du rotor: Diamètre: 1500mm; Largeur: 2000mm; Vitesse: ~750 RPM
Spécifications matérielles: Housing – Fabricated AR400 Steel; Hammers – Forged Alloy Steel with Tungsten Carbide Tips (Standard); Plaques de disjoncteur / Grates – HiChrome Alloy Castings
Dimensions physiques (L x l x H): Environ. 3m x 2m x 2m
Plage de fonctionnement environnementale: Plage de température ambiante (20°C à +45°C); Dusttight construction rated up to IP65

6. SCÉNARIOS D'APPLICATION

Usine de production de granulats – Traitement du calcaire

Challenge A quarry operation experienced premature failure of standard hammers every three weeks when processing abrasive silicacontaminated limestone belts.
Solution Implementation of two HPA4000 hammer mills configured with tungsten carbidetipped reversible hammers.
Results Wear part life extended to seven weeks per set; annual consumable costs reduced by $42k per mill; plant achieved scheduled maintenance alignment with other circuit components.

Industrial Mineral Processing – Gypsum Preparation

Challenge Inconsistent moisture content in feedstock caused frequent clogging of discharge grates in an existing mill system.
Solution The HPA4000 was installed with an optional internal breaker plate heating system and larger openarea grate design.
Results Clogging incidents reduced from weekly occurrences to fewer than four per year; plant throughput stabilized at design capacity of 150 TPH regardless of seasonal feedstock variations.

7. CONSIDÉRATIONS COMMERCIALES

The HPA4000 hammer mill is offered as a complete package including motor drives,Courroies trapézoïdales,and starter equipment on a common base frame.

Niveaux de tarification & Possibilités
Configuration de base (HPA4000STD): Includes standard alloy hammers and manganese liners.
Forfait Haute Abrasion (HPA4000HA): Upgraded tungsten carbidetipped hammers and chrome alloy liners (~+18% investment).
Automation Ready Package (HPA4000AR): Includes vibration sensors,sondes de température,and integration wiring for plant SCADA systems (~+12% investment).

Forfaits de services:
1année / 2000hour comprehensive parts & labor warranty included.Factorysupported annual inspection contracts available.Extended wearpart supply agreements offer guaranteed pricing.

Financing options include capital lease agreements tailored for municipal contractors,mine development projects,and private aggregate producers seeking predictable monthly expenditure models over 36, 60, or 84month terms.Equipment tradein programs are evaluated casebycase

8. FAQ

Q What are the primary factors that determine throughput capacity?
A Capacity is dictated by feed material bulk density,Bond Work Index hardness,and target output size.A detailed lab analysis of your sample determines precise tonnage ratings

Q Is this hammer mill compatible with our existing PLC control system?
A Yes.The HPA4000 control panel includes standard Modbus TCP/IP protocol outputs.All critical operational data can be integrated into most modern plant control rooms

Q Quel est le délai de livraison prévu à partir de la passation de la commande?
A Standard configuration units ship within 14 weeks.Custom configurations may require additional engineering time which will be specified during project quotation

Q How does this design address operator safety?
A The unit exceeds CE standards featuring zeromotion electrical interlocks on all access doors ensuring the rotor cannot be energized during inspection Hydraulic door assists eliminate manual handling risks

Q Des garanties de performance sont-elles fournies?
A Yes.Based on certified lab analysis of your provided feedstock we guarantee final product gradation curves within +/5%and specific energy consumption figures as quoted