1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are inconsistent feed materials and rising operational costs impacting your comminution circuit's profitability? Common challenges in size reduction include:

Temps d'arrêt excessif: Frequent maintenance stops for screen changes, hammer replacement, or bearing failures disrupt your entire production line.
Distribution granulométrique incontrôlée: Inconsistent output leads to downstream processing inefficiencies, affecting briquetting, pelletizing, or chemical extraction yields.
Coûts opérationnels élevés: Premature wear of consumable parts and high energy consumption per ton processed directly erode your margin.
Problèmes de manutention: Processing sticky, moist, or fibrous materials leads to clogging, reducing throughput and creating operational hazards.

Is your current crushing solution flexible enough to handle varying feedstock? Are you achieving the optimal balance between particle size control and total cost of ownership?

2. APERÇU DU PRODUIT: HAMMER MILL FOR INDUSTRIAL SIZE REDUCTION

A hammer mill is a robust impact crusher designed for hightonnage reduction of mediumhard to soft materials. Its operation is based on a simple yet effective mechanical process:

1. Présentation du flux: Material is introduced into the grinding chamber via a controlled feed system (par ex., alimentateur vibrant, convoyeur à bande).
2. Réduction de taille: Marteaux à rotation rapide (monté sur un rotor) impact the material, shattering it upon impact with the breaker plates and through particleonparticle attrition.
3. Particle Discharge: Sized material passes through a screen or grate lining the mill's perimeter, determining the final top particle size.

Champ d'application: Ideal for crushing/mineral processing (charbon, calcaire, gypse), recyclage (déchets électroniques, construction debris), agricultural processing (biomasse, grains), and chemical manufacturing. Limite clé: Ne convient pas aux travaux très durs, matériaux abrasifs (par ex., granit, highsilica ores) where wear costs would be prohibitive; jaw or cone crushers are better suited for primary reduction of such feedstocks.

3. CARACTÉRISTIQUES PRINCIPALES

Ensemble de rotor robuste | Base technique: Forged or cast rotor discs on a balanced shaft | Avantage opérationnel: Sustains high inertia for consistent crushing with less power fluctuation; handles tramp material with reduced risk of catastrophic failure | Impact sur le retour sur investissement: Lower vibration extends bearing life by up to 40%, reducing unscheduled downtime and part replacement costs.

Système d'usure QuickChange | Base technique: Interlocking/reversible hammers and modular breaker plates | Avantage opérationnel: Operators can reverse hammers or replace screens/liners in under 2 hours versus a full shift | Impact sur le retour sur investissement: Minimizes production stoppages; extends consumable life cycle by utilizing all hammer edges.

Système de décharge AirAssist | Base technique: Integrated fan and air handling within the mill housing | Avantage opérationnel: Actively moves finished material through the screen, preventing clogging with damp or fine feeds | Impact sur le retour sur investissement: Maintains rated throughput in challenging conditions; improves yield by reducing heatrelated degradation of sensitive materials.

Dynamic Screen Selection | Base technique: Perforated metal screens or bar grates in multiple configurations | Avantage opérationnel: Precise control over final product top size from coarse (25mm+) to fine (1mm) caractéristiques | Impact sur le retour sur investissement: Enables one machine to produce multiple product grades for different contracts or downstream processes.

Ports de surveillance des vibrations | Base technique: Integrated sensor mounts on bearing housings | Avantage opérationnel: Facilitates connection to condition monitoring systems for predictive maintenance alerts | Impact sur le retour sur investissement: Prevents secondary damage from misalignment or bearing wear; allows maintenance scheduling during planned stops.

HeavyDuty Baseframe & Logement | Base technique: Unitized steel plate construction with bolton access panels | Avantage opérationnel: Absorbs operational loads without distortion; provides safe, easy access for inspection and service | Impact sur le retour sur investissement: Ensures longterm structural integrity over a 15+ year service life in demanding environments.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Notre solution de broyeur à marteaux Avantage documenté |
| : | : | : |
| Tonnes par heure par kW (Calcaire) | 4.5 5.2 tph/kW | 5.8 6.4 tph/kW |
| Hammer Lifespan (Réversible) | 400 600 heures d'ouverture | 750 900 heures d'ouverture |
| Temps de changement d'écran (Ensemble complet) | 4 6 heures de temps d'équipage 50% plus rapide |
| Niveau de bruit à 1 Mètre <105 dBA <98 dBA Improved operator environment |

Data based on field performance reports from installations processing similar materials.

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: dépendant du modèle, from pilotscale (5 TPH) to heavy industrial throughput (>250 TPH).
Exigences d'alimentation: Depuis 75 kW à plus 1500 kW motor drive; configured for standard industrial voltages (400V/690V/3300V).
Vitesse du rotor: Adjustable based on application; gamme typique de 750 RPM (coarse crushing) à 3000 RPM (fine grinding).
Spécifications matérielles: Housing constructed from AR400 steel plate; Hammers available in highchrome cast iron, acier au manganèse, or carbidetipped options; Screens in hardened steel or abrasionresistant alloys.
Dimensions physiques: Varie considérablement selon le modèle; largest industrial units may require ~8m L x 4m W x 5m H footprint during operation.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dusttight housings available for operations requiring containment.

6. SCÉNARIOS D'APPLICATION

Traitement des minéraux – Production de chaux agricole

Défi: A quarry needed to produce both coarse aglime and fine powdered lime from the same limestone deposit using one machine fleet.
Solution: Implementation of a largecapacity hammer mill equipped with an airassist discharge and quickchange screen system.
Résultats: The plant achieved dualproduct capability by changing screens during scheduled shifts. Le débit a augmenté de 22% due to reduced clogging with fines, and energy consumption per ton dropped by an estimated 15%.

Recycling – Construction & Demolition Waste Processing

Défi: A recycling facility faced excessive wear and unpredictable downtime when processing mixed C&D waste containing abrasive concrete and softer wood/plasterboard.
Solution: A customized hammer mill featuring a hybrid hammer design (carbide tips on leading edges) and extraheavyduty bearings was installed.
Résultats: Wear part lifecycle extended by over 60% on abrasive fractions. The mill’s high inertia allowed it to process mixed loads without stalling, increasing overall plant availability.

7. CONSIDÉRATIONS COMMERCIALES

Hammer mill procurement is structured around core capacity and customization:

Niveaux de tarification: Entrylevel standard models offer proven designs for common materials. Midrange models include customization like airassist or special rotors. Hightier solutions are fully engineered systems with integrated feeding/discharge conveyors,dust collection,and automation controls.
Fonctionnalités facultatives: Key upgrades include explosionproofing for combustible dust,silencing packages,motor starters/VFDs for soft start & speed control,and advanced bearing temperature monitors.
Forfaits de services: Comprehensive support ranges from basic commissioning & operator training to annual inspection contracts and guaranteed spare parts delivery schedules( par exemple, expédition de pièces critiques en 48 heures).
Options de financement: Commercial buyers can access equipment leasing structures,tailored rentaltoown programs for projectbased work,and standard purchase order financing through partner institutions

8 FAQ

Q What factors determine whether my material is suitable fora hammer mill versus another crusher type?
A Material hardness moisture content abrasivenessand desired reduction ratio are key Hammer mills excel on brittle friable materialswith moisture content below 15% They are less suitedfor extremely hard highly abrasive rockswhere wear costs dominate

Q How doesa hammer mills output comparetoa jaw crusheror roll crusher?
A A hammer mill typically produces more finesand acubical product due its impact action It offers higher reduction ratiosin asingle stage( upto 20 ) comparedto compression crushers making it ideal formid stage secondaryor tertiary crushing where precise shapeis less critical than size control

Q Can existing motorsand drivesbe usedwith anew hammer mill?
A Possibly Engineering reviewsof your existing motor specs power supply voltage phase frequency must be conductedto ensure compatibilitywiththe new mills rotor inertiaand starting torque requirements Variable Frequency Drives VFDs can often bridge gapsbut require sizingby our engineers

Q Whatisthe typical lead timefor acustomizedhammer millsolution?
A Lead times vary Standard models may shipin 8 weeks Fully customized units involving specific metallurgy special fabricationor complex system integration typically require 14 weeksfrom finalized engineering drawings

Q Des garanties de performance sont-elles offertes?
A Yes performance guaranteesbasedon capacity power consumptionand product sizingare providedas partof the commercial proposal These guaranteesare contingenton supplying agreed feed material samplesand operating within specified parameters during commissioning tests