1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Gérez-vous les coûts récurrents et les goulots d’étranglement opérationnels de votre processus de réduction de taille? Inconsistent particle size, remplacement des pièces d'usure excessive, and unplanned downtime directly impact your bottom line. Common challenges with hammer mill operations include:

Coûts de maintenance élevés: Remplacement fréquent des marteaux, écrans, and liners due to premature wear from abrasive materials or improper impact dynamics.
Production Inconsistency: Fluctuating output fineness and capacity caused by screen clogging, rotor imbalance, or inadequate air handling, leading to product quality issues.
Consommation d'énergie excessive: Inefficient grinding chambers and drive systems that draw more power than necessary for the required throughput, gonfler les dépenses opérationnelles.
Temps d'arrêt imprévus: Failures of critical components like bearings or the rotor shaft, often resulting from overheating or vibration outside of design parameters, arrêter toute votre chaîne de traitement.

How do you control these variables to achieve predictable throughput, consistent product specs, et un coût inférieur? The answer lies in selecting a hammer mill engineered to address these specific failure points.

2. APERÇU DU PRODUIT: INDUSTRIAL HEAVYDUTY HAMMER MILL

This equipment is a directdrive or beltdriven secondary/tertiary crusher and grinder designed for highvolume reduction of mediumhard to soft materials. Its core function is to transform feed stock into a predetermined particle size through controlled impact fragmentation.

Flux de travail opérationnel:
1. Présentation du flux: Material is fed via vibratory feeder or conveyor into the grinding chamber.
2. Impact & Réduction de taille: A highspeed rotor assembly with freely swinging or fixed hammers repeatedly strikes the incoming material, shattering it upon impact with the hammers and against the integrated breaker plate.
3. Classification des particules: Les particules calibrées traversent un tamis perforé entourant la chambre du rotor; particles larger than the screen apertures are retained for further impact.
4. Décharge & Air Handling: Reduced material exits via gravity or is conveyed pneumatically; optional integrated fan systems assist material flow and control dust.

Champ d'application: Idéal pour le traitement des granulats, calcaire, matériaux de construction recyclés, déchets de bois, biomasse, et certains minéraux industriels. Not suited for highly abrasive materials (par ex., sable de silice sans revêtements spécialisés) or very hard materials (au-dessus de Mohs 7) où les coûts d'usure deviennent prohibitifs.

3. CARACTÉRISTIQUES PRINCIPALES

Système de rotor réversible | Base technique: Symmetrical rotor design allows endforend reversal of hammer sets | Avantage opérationnel: Operators can utilize both leading edges of each hammer, doubling service life before changeout | Impact sur le retour sur investissement: Réduit les coûts d'inventaire des marteaux jusqu'à 50% and extends maintenance intervals by an estimated 100%

Doublures d'usure segmentées | Base technique: Bolton liner plates manufactured from AR400 or chromium carbide steel | Avantage opérationnel: Enables targeted replacement of worn sections in highimpact zones without removing entire mill housing | Impact sur le retour sur investissement: Lowers liner replacement cost by approximately 30% and reduces liner change downtime by an estimated 40%

Conception de flux d'air dynamique | Base technique: Dynamique des fluides computationnelle (CFD)optimized chamber geometry and optional induceddraft fan | Avantage opérationnel: Prevents screen blinding by efficiently removing fines, maintains steady throughput, and reduces heat buildup | Impact sur le retour sur investissement: Improves sustained capacity by 1520% and contributes to more stable power consumption

Coussinets de surveillance des vibrations | Base technique: Integrated machined mounting pads for permanent vibration sensors | Avantage opérationnel: Facilitates predictive maintenance by allowing direct monitoring of rotor balance and bearing condition | Impact sur le retour sur investissement: Helps prevent catastrophic bearing/rotor failures, potentially saving over 90% of associated repair costs and production losses

Cartouche d'écran QuickChange | Base technique: Slideout screen frame assembly with hydraulic or manual unlocking mechanism | Avantage opérationnel: Allows full screen change in under 30 minutes versus several hours with traditional boltin designs | Impact sur le retour sur investissement: Minimizes downtime for product size changes or screen maintenance, augmentation de la disponibilité des plantes

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Notre solution de broyeur à marteaux | Avantage documenté |
| : | : | : | : |
| Tonnage par durée de vie du jeu de marteaux (Calcaire Abrasif) | 80,000 100,000 Tonnes | 180,000 220,000 Tonnes | +110% Amélioration |
| Temps de changement d'écran (Procédure complète) | 2.5 4 Heures | <45 Minutes (with cartridge system)| Jusqu'à 81% Gain de temps |
| Consommation d'énergie spécifique (kWh/tonne) Varie selon le matériau| Baseline = X kWh/Ton| X 12% kWh/tonne| Jusqu'à 12% Amélioration |
| Temps moyen entre les pannes (MTBF) Roulements critiques| ~8 000 heures de fonctionnement| >12,000 Heures d'ouverture| +50% Amélioration |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Modèle dépendant de 15 TPH à plus 300 TPH for aggregate applications.
Exigences d'alimentation: Depuis 75 kW (100 HP) à 750 kW (1000 HP), configured for VFD or direct online starting.
Assemblage du rotor: Acier massif forgé ou tôle d'acier fabriquée; diamètre de 800mm à 1800mm; width commensurate with capacity.
Spécifications matérielles: Housing – Mild steel plate with AR400/AR500 liners; Hammers – Forged alloy steel with tungsten carbide hardfacing options; Screens – Hardened manganese or stainless steel perforated plate.
Dimensions physiques (Exemple de modèle): Environ. Longueur: 3.5m; Width 2.8m; Height 2.2m (hors trémie d'alimentation).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dusttight housing rated for typical indoor/outdoor industrial installation.

6. SCÉNARIOS D'APPLICATION

Agrégat & Limestone Quarrying Plant

Challenge A midsized quarry faced excessive downtime every six weeks for hammer rotation and liner replacement on their primary secondary crusher hammer mill costing over $25k annually in parts alone plus production losses.

Solution Implementation of our heavyduty hammer mill featuring the reversible rotor system and segmented wear liners was completed during a planned shutdown.

Results Field data shows a reduction to four maintenance events annually with parts consumption down by approximately $14k per year combined with an estimated $18k savings in recovered production time—delivering full payback on the equipment in under two years.

Municipal Solid Waste Recycling Facility

Challenge Processing construction & demolition debris led to frequent screen clogging from fibrous materials variable feed density causing hourly throughput swings between extremes requiring constant operator intervention.

Solution Installation included our model optimized with dynamic airflow design ensuring consistent negative pressure within the grinding chamber paired with a quickchange screen system

Results Operators report stable operation achieving nameplate capacity consistently Screen blinding incidents reduced by over % allowing one operator to manage multiple lines Quantifiable results show a % increase in monthly processed tonnage using similar energy input

7 CONSIDÉRATIONS COMMERCIALES

Equipment pricing is structured across three primary tiers based on capacity robustness:

1 Standard Duty Models Engineered for consistent nonabrasive materials like wood biomass Base pricing includes standard manganese hammers screens
2 Heavy Duty Models The most common selection for aggregate mineral processing Includes reversible rotors segmented liners highergrade bearings
3 Severe Duty Models Configured for challenging applications featuring maximum hardfacing premium bearing packages advanced monitoring interfaces

Optional Features Upgrades include automated lubrication systems explosion suppression packages various inlet chute designs special alloy screens

Service Packages Available plans range from basic preventative maintenance kits through comprehensive annual inspection programs up to full performanceguaranteed service contracts covering parts labor

Financing Options Flexible commercial structures are available including capital lease operating lease longterm rental purchase agreements tailored support project financing models

8 FAQ

Q What are my options if my feed material abrasiveness changes after purchase?
A The modular wear protection system allows adaptation You can upgrade liner hammer materials during scheduled service intervals without replacing the core mill structure

Q How does this hammer mill handle wet or sticky feed material?
A While all mills have limitations operational protocols combined with optional breaker plate designs internal air evacuation can mitigate issues We recommend providing sample material for controlled testing at our facility

Q What is required for foundation installation?
A Detailed foundation drawings anchor bolt templates are provided All models require a reinforced concrete foundation sized appropriately based on dynamic loads Vibration isolation pads are an available option

Q Can this equipment integrate with my existing PLC control system?
A Yes standard models provide hardwired signals start/stop fault Modern units offer optional Profibus Ethernet/IP communication modules for full integration into plant SCADA systems

Q Quel est le délai de livraison typique à partir de la mise en service de la commande?
A Lead times vary based on model specification complexity Current standard lead times range between weeks Custom configurations may require additional engineering time