1. PAINPOINT DRIVE NOLEING

Та тууштай үйлдвэрлэл явуулдаг карьерын үйл ажиллагааг удирдаж байна уу, highquality railway ballast is compromising your bottom line? Сорилтууд нь тодорхой бөгөөд өртөг өндөртэй байдаг. Inconsistent particle shape and size distribution lead to high flakiness index aggregates, resulting in ballast rejection and wasted material. Frequent liner wear in crushing chambers increases maintenance downtime and consumable costs. Inefficient screening recirculation creates bottlenecks, үйлдвэрийн нийт нэвтрүүлэх чадварыг хязгаарлах. Each hour of unplanned downtime represents significant lost revenue from both ballast production and your core aggregate products.

How do you increase ballast yield without sacrificing the quality specifications mandated by rail authorities? Can you reduce the total cost per ton for this critical product while maintaining system reliability? Шийдэл нь зориулалтын инженерийг сонгох явдал юм ил уурхайн тогтворжуулагч бутлах төхөөрөмж designed to address these exact operational pressures.

2. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ

Энэхүү бүтээгдэхүүний шугам нь хүнд даацыг агуулдаг, secondary and tertiary crushing solutions specifically configured for highquality quarry ballast production. The typical operational workflow integrates seamlessly into an existing plant: (1) Primary crushed feed (ихэвчлэн 250 мм) is conveyed to the ballast crusher; (2) Material undergoes progressive compression crushing within a specially configured chamber; (3) The crushed product is discharged onto a dedicated sizing screen; (4) Onspec material (+22mm/63mm, as per local standards) is sent to stockpile, while oversize is recirculated; (5) Undersize is redirected for production of other aggregate grades.

Application scope includes dedicated ballast production lines within hard rock quarries (боржин чулуу, сагссах, шохойн чулуу). Key limitations involve feed size compatibility with primary crusher discharge and the requirement for a closedcircuit system with accurate screening for optimal yield.

3. ҮНДСЭН ОНЦЛОГ

Нарийвчилсан танхимын геометр | Техникийн үндэслэл: Multizone crushing profile with optimized nip angles | Үйл ажиллагааны ашиг тус: Бөөм хоорондын бутлах үйл ажиллагааг дэмжинэ, producing superior cubical product with low flakiness index (<15% ердийн) | ROI нөлөө: Борлуулах боломжтой тогтворжуулагчийн гарцыг нэмэгдүүлнэ 815%, reducing waste and maximizing revenue from each ton of raw feed.

Hydroset CSS тохируулга | Техникийн үндэслэл: Hydraulic piston for closedside setting adjustment under load | Үйл ажиллагааны ашиг тус: Operators can finetune product gradation in minutes without stopping production, responding to changes in feed characteristics. | ROI нөлөө: Minimizes adjustment downtime by up to 90% гарын авлагын шилний системтэй харьцуулахад, тогтмол үзүүлэлтийн гаралтыг хангах.

Хүнд даацын ротор & Холбогдол | Техникийн үндэслэл: Forged alloy steel rotor supported by oversized spherical roller bearings | Үйл ажиллагааны ашиг тус: Sustains high inertia for efficient crushing of hard abrasive rock with minimal vibration. | ROI нөлөө: Үндсэн бүрэлдэхүүн хэсгүүдийн ашиглалтын хугацааг уртасгана, reducing risk of catastrophic failure and associated repair costs and extended downtime.

Доторлогооны материалын сонголтууд | Техникийн үндэслэл: Selection of manganese steel grades and composite alloys based on rock abrasiveness | Үйл ажиллагааны ашиг тус: Provides optimal wear life versus cost balance for specific mineralogy. | ROI нөлөө: Reduces costperton for wear liners by 2040% through targeted material selection and extended changeout intervals.

Integrated Automation Interface | Техникийн үндэслэл: PLCcompatible sensors for CSS, цахилгаан дай судаг, and bearing temperature monitoring | Үйл ажиллагааны ашиг тус: Enables realtime performance tracking and predictive maintenance alerts, integrating with plantwide control systems. | ROI нөлөө: Prevents unplanned stops through condition monitoring and allows datadriven optimization of throughput versus power consumption.

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт | Манай карьерын тогтворжуулагчийг бутлах шийдэл | Давуу тал (% сайжруулалт) |
| : | : | : | : |
| Ballast Product Yield (материалыг шалгах) | 6575% of crusher output stream| 7885% of crusher output stream| +10% дундаж |
| Liner Wear Life (in abrasive granite) | 450,000 550,000 луу| 600,000 750,000 луу| +25% дундаж |
| Бэлэн байдал (хуваарьтай & төлөвлөөгүй) | 9294%| 9698%| +4 хувь оноо |
| Тодорхой эрчим хүчний хэрэглээ (кВт.ц/тн)| Varies widely by design| Optimized chamber design reduces recirculating load| Шалтгаална, хамаарна 12% |
| Зэрэглэлийн тууштай байдал (maintaining spec)| Requires frequent manual CSS checks| Hydroset automation allows continuous control| Deviation reduced by ~60% |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Хүчин чадлын хүрээ: -аас тохируулах боломжтой 200 дээр нь 1,200 метр тонн цагт бэлэн тогтворжуулагч бүтээгдэхүүн.
Эрчим хүчний шаардлага: -аас мотор жолоодох 200 кВт хүртэл 600 kw, compatible with standard highvoltage quarry supply.
Материалын үзүүлэлтүүд: Шахалтын бат бэхийн зориулалтаар бүтээгдсэн >150 MPa abrasive rock. Standard wear liners are ASMT A128 Grade B3/B4 manganese steel.
Физик хэмжээсүүд: Typical footprint ranges from ~6m x 4m for midrange models. Total installed weight from 25t to 70t.
Байгаль орчны үйл ажиллагааны хүрээ: 20°С-аас +45°С хүртэлх орчны температурт зориулагдсан. Dust sealing systems are rated for continuous outdoor operation.

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

Regional Rail Network Expansion Project

Сорилт: A contractor needed guaranteed supply of Class I railway ballast meeting stringent national rail specs (З хэмжээ & FI). Their existing cone crusher produced excessive fines and flaky material.
Хариу: Implementation of a tertiarystage quarry ballast crushing equipment configured with a cubical chamber profile and paired with a highcapacity horizontal screen.
Үр дүн: Ballast yield improved from 68% нь 82%. Product consistently passed all quality audits, enabling the contractor to secure a premium supply agreement.

Granite Quarry Diversifying into Rail Supply

Сорилт: A quarry producing road aggregates sought to enter the rail ballast market but faced high wear costs and poor shape when processing their very abrasive granite.
Хариу: Installation of a dedicated ballast crushing circuit featuring our solution with optional XT alloy liners designed for highabrasion applications.
Үр дүн: Давхаргын ашиглалтын хугацаа нэмэгдсэн 32%, making ballast production economically viable. The quarry successfully diversified its revenue streams within the same rock reserve.

7. АРИЛЖААНЫ ХЭРЭГЛЭЭ

Pricing tiers are structured around machine capacity and optional features:
Стандарт түвшин: Highefficiency base model for standard hard rock applications.
Гүйцэтгэлийн түвшин: Includes automation package (Hydroset+), дэвшилтэт хяналтын мэдрэгч, and premium baseline liners.
Custom Tier: Customized wear package metallurgy or specific motor configurations for unique site conditions.

Key optional features include automated lubrication systems, spillage conveyor packages, and advanced vibration monitoring telemetry.

Service packages range from basic commissioning support to comprehensive multiyear maintenance agreements covering planned inspections, liner changeout labor support, болон тэргүүлэх ач холбогдол бүхий эд ангиудыг илгээх.

Financing options include traditional capital equipment loans as well as productivitybased leasing structures that align payments with operational tonnage targets.

8. Түгээмэл асуултууд

1. Энэ төхөөрөмж нь манай одоо байгаа анхдагч хацарт бутлуур, шигших үйлдвэртэй нийцэж байгаа эсэх?
Тиймээ. Our engineering team will review your primary crusher's discharge gradation and your screen box configurations to ensure seamless integration and optimize closedcircuit flow rates.

2. What is the expected impact on our overall plant electrical load?
Field data shows that due to higher efficiency in particle breakage and reduced recirculating load on screens overall circuit energy use per ton of finished ballast often decreases despite the addition of a dedicated crusher.

3. How does the maintenance schedule compare to other conetype crushers?
With common access points standardized service intervals remain similar however key component lives particularly bearings are extended reducing the frequency of major interventions lowering total lifetime service hours

4. Can you guarantee final product gradation will meet our country's railway specifications?
While final product depends on feed characteristics screen configuration we provide performance modeling based on your rock test data We guarantee the mechanical performance of the equipment itself

5. Ердийн хүргэлтийн хугацаа гэж юу вэ?
For standard models lead times range from months depending on current manufacturing capacity Custom configurations may require additional time

6. Are training programs provided for our operations maintenance staff
Comprehensive onsite training during commissioning is included covering safe operation routine maintenance procedures troubleshooting guidelines

7 Ямар баталгаат нөхцөл хамаарна
We offer month warranty on all parts against manufacturing defects Extended warranty coverage is available through our service package agreements