1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing recurring bottlenecks and hidden costs in your size reduction process? Distribution granulométrique incohérente, remplacement des pièces d'usure excessive, and unplanned downtime for maintenance are not just operational nuisances—they directly erode your profitability and throughput. Considérez ces défis communs:
Coût opérationnel élevé: Remplacement fréquent des marteaux, écrans, and liners due to premature wear, compounded by labor costs for changeovers.
Sortie incohérente: Variable feed materials lead to an inconsistent final grind size, compromising downstream process efficiency and product quality.
Temps d'arrêt excessif: Longue, complex maintenance procedures for internal inspections and part replacements halt your entire production line.
Inefficacité énergétique: Older or poorly designed hammer mills waste significant power on vibration, chaleur, and ineffective impact, rather than productive comminution.
Poussière & Pollution sonore: Inadequate sealing and damping create environmental and safety hazards, leading to potential compliance issues and worker discomfort.

Is your current equipment delivering predictable performance and total cost of ownership? The solution lies in selecting a hammer mill engineered not just to crush material, but to optimize your entire operational workflow.

2. APERÇU DU PRODUIT

Our industrial hammer mill is a heavyduty impact crusher designed for highvolume reduction of mediumhard to soft materials. It is a core component in aggregate production, prétraitement des minéraux, limestone grinding for agricultural lime or flue gas desulfurization (Groupe de discussion), et opérations de recyclage.

Flux de travail opérationnel:
1. Alimentation contrôlée: Le matériau est introduit via un système d’alimentation régulé (par ex., convoyeur à bande, alimentateur vibrant) dans la chambre de broyage.
2. Impact à haute vitesse: Un ensemble rotor équipé de marteaux libres ou rigides tourne à grande vitesse, repeatedly striking the incoming material against breaker plates.
3. Classement des tailles: Crushed particles pass through a surrounding screen or grate; only material meeting the specified size exits the chamber.
4. Décharge & Transport: Sized material is discharged via gravity or pneumatic system for further processing or stockpiling.

Champ d'application & Limites:
Idéal pour: Calcaire, gypse, charbon, agrégats, recycled asphalt pavement (RAP), béton de démolition, aboyer, et autres matériaux friables.
Limites: Non recommandé pour les matériaux très abrasifs (par ex., sable de silice) sans options d'alliages spécifiques, métaux hautement ductiles, or materials with high moisture content that may cause clogging without proper conditioning.

3. CARACTÉRISTIQUES PRINCIPALES

Système de rotor réversible | Base technique: La conception symétrique du rotor permet une rotation frontale des marteaux | Avantage opérationnel: Double la durée de vie des bords d'attaque du marteau avant le remplacement; reduces inventory by standardizing parts | Impact sur le retour sur investissement: Cuts wear part costs by up to 40% over the lifecycle of the unit

Équilibrage dynamique | Base technique: Computeraided rotor balancing postassembly at operating RPM | Avantage opérationnel: Minimise la transmission des vibrations aux roulements et aux fondations; permet un fonctionnement à grande vitesse plus fluide | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements d'en moyenne 30% and reduces structural fatigue

QuickAccess Clamshell Design | Base technique: Hinged housing sections secured by hydraulic rams or largebore bolts | Avantage opérationnel: Full interior access for inspection, changements d'écran, or hammer rotation in under 30 minutes | Impact sur le retour sur investissement: Reduces standard maintenance downtime by approximately 70%, augmentation du débit annuel

Doublures d'usure segmentées | Base technique: Bolton liner plates manufactured from AR400 or chromium carbide alloys | Avantage opérationnel: Individual sections can be replaced as needed without dismantling the entire mill housing | Impact sur le retour sur investissement: Lowers liner replacement cost by targeting only worn areas; simplifies logistics

Assistance aérienne & Intégration de la suppression de la poussière | Base technique: Sealed housing with ports for negative pressure systems or controlled air flow | Avantage opérationnel: Manages internal airflow to reduce heat buildup and directs fine particulates to collection systems | Impact sur le retour sur investissement: Improves operational safety (reduces explosion risk), assure la conformité environnementale

Roulements à rouleaux sphériques robustes | Base technique: Oversized bearing housings with labyrinth seals and grease purge systems | Avantage opérationnel: Handles high radial loads from unbalanced feed conditions; excludes contaminants | Impact sur le retour sur investissement: Provides reliable service in highshock environments with extended lubrication intervals

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Notre solution de broyeur à marteaux | Avantage documenté |
| : | : | : | : |
| Tonnage par kWh (Limestone 6mm) | 8 10 Tonnes/kWh | 11 13 Tonnes/kWh| +2030% Efficacité énergétique |
| Temps de changement d'écran (Ensemble complet) | 4 6 Heures| 120k MTon| +50% Fiabilité améliorée |
| Niveau de bruit à 1 Mètre (dBA) >100 dBA|<95 dBA with standard housing|<5 Réduction des dBA |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Modèle dépendant de 25 TPH à plus 300 TPH on limestone (25mm feed to 3mm product).
Exigences d'alimentation: Depuis 75 kW (100 HP) jusqu'à 750 kW (1000 HP), configured for VSD control where applicable.
Diamètre du rotor & Largeur: From Ø800mm x 800mm up to Ø2000mm x 2500mm.
Matériaux de construction: Mainframe – Fabricated steel plate (min. 25mm). Hammers/Screens – Highcarbon steel/AR400/Chrome iron alloys optional. Liners – AR400 standard; ceramic composite optional.
Dimensions physiques & Poids: Varie considérablement selon le modèle; largest units require planned foundation work (~1540 metric tons).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C. Dust ingress protection rating of IP54 standard.

6. SCÉNARIOS D'APPLICATION

Usine de production de chaux agricole

Challenge A producer needed consistent fine grind (2mm) of limestone at 150 TPH but faced weekly downtime for screen changes and monthly hammer replacements due to abrasive silica content in the feedstock.

Solution Implementation of a heavyduty hammer mill featuring a reversible rotor with tungsten carbidetipped hammers and quickaccess clamshell doors.

Results Screen change time reduced from one full shift (8 heures) à moins de deux heures. Hammer life extended from ~10k tonnes to over 28k tonnes. Annual availability increased by an estimated 12%, achieving target throughput with one less scheduled maintenance day per month.

Construction & Installation de recyclage de démolition

Challenge Processing mixed C&D waste into clean aggregate was hampered by frequent jamming from noncrushables (brins d'armature) causing severe rotor damage and belt slippage.

Solution Installation included a nonclogging steppedgrate screen design paired with shearbolt protected hammers on a lowinertia rotor that could be stopped quickly.

Results Incidents of catastrophic jamming dropped by over 90%. The shearbolt system protected the main shaft and bearings during overload events. Overall plant uptime improved significantly while reducing repair part expenditures by an estimated 35% annuellement.

7. CONSIDÉRATIONS COMMERCIALES

Nos broyeurs à marteaux sont proposés sur trois niveaux principaux:

1. Standard Duty Series For consistent feed materials requiring reliable performance at lower capital outlay.
2 Heavy Duty Series The core offering described here includes all major features like reversible rotors quickaccess design ideal for most mining aggregate applications
3 Extreme Duty Series Engineered for maximum abrasion resistance featuring specialized alloys automated lubrication systems advanced monitoring sensors

Optional Features Upgrades include programmable logic controller PLCbased monitoring packages automatic greasing systems explosion suppression systems custom discharge configurations

Service Packages Available options range from basic commissioning supervision through comprehensive multiyear planned maintenance agreements including guaranteed parts availability priority technical support

Financing Options We work with international export credit agencies project finance partners equipment leasing companies Flexible payment structures can be tailored including milestone payments upon delivery commissioning

8 FAQ

Q What level of preparation is required for my feedstock before using this hammer mill
A For optimal performance feed should be prescreened to remove fines already at specification size Maximum feed size should not exceed 80% of the screen aperture opening Material moisture content should generally remain below 15% depending on clay content

Q How does this hammer mill integrate with my existing conveying dust collection systems
A Our engineering team provides detailed interface drawings specifying inlet outlet flange dimensions load points electrical requirements Standard units are designed for integration into both gravityfed pneumatic conveying circuits

Q Quel est le délai d'exécution typique à partir de la mise en service de la passation des commandes
A Lead times vary based on model specification For standard heavyduty models expect approximately 1620 weeks exworks including manufacturing testing documentation preparation Expedited production may be available subject inquiry

Q Can you provide wear part consumption estimates specific my material analysis
A Yes Based on your provided sample we conduct laboratory testing generate a detailed wear forecast outlining expected service life hammers screens liners under defined operating conditions This forms basis our guaranteed performance agreements

Q Quelle formation a dispensé notre personnel de maintenance des opérations
A Comprehensive training included covers safe operation routine maintenance troubleshooting procedures conducted both our facility during onsite commissioning We provide detailed operation manuals parts lists instructional videos