1. PAINPOINT DRIVE NOLEING

Are you managing a quarry ballast production operation where inconsistent feed material and equipment limitations are eroding your margins? Нийтлэг бэрхшээлүүд орно:

Их зогсолт & Засвар үйлчилгээний зардал: Доторлогоо байнга солигддог, холхивчийн гэнэтийн эвдрэл, and clogging from sticky, highfines material lead to excessive nonproductive hours and high parts expenditure.
Бүтээгдэхүүний хэлбэр муу & Ургац: Inefficient crushing chambers produce excessive flaky or elongated particles, failing to meet stringent railway or construction ballast specifications (жишээ нь e., IN 13450). This results in a lower percentage of premium, saleable product.
Inefficient Energy Consumption: Older or poorly configured crushing stages consume disproportionate power per ton of final product, directly impacting operational costs.
Inflexible Capacity: Fixed plants cannot easily adapt to fluctuating demand or varying feed hardness, leading to bottlenecks or underutilized assets.
Чандруу & Noise Compliance Risks: Open crushing and screening processes generate significant dust and noise, creating environmental compliance challenges and potential site operational restrictions.

Is your current setup delivering the consistent cubicle product shape, high availability, and low costperton required to remain competitive? The solution lies in a purposeengineered quarry ballast crushing equipment assembly.

2. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ

The Advanced Quarry Ballast Crushing Plant is a stationary or semimobile primary, дунд, and tertiary crushing system engineered specifically for the highvolume production of highquality railway ballast and construction aggregates.

Үйл ажиллагааны ажлын урсгал:
1. Анхдагч бууралт: Dumpfed primary jaw crusher reduces blasted rock to a manageable size (ихэвчлэн <250mm).
2. Хоёрдогч бутлах & Хэлбэржүүлэх: A dedicated cone crusher, configured for ballast production, further reduces material and begins critical particle shaping.
3. Tertiary Finishing & Дэлгэц авах: A vertical shaft impactor (Бүгд) or a tertiary cone crusher with a fine chamber performs the final stage of crushing and cubicity optimization. Integrated screening decks precisely separate the final product into specified size fractions (жишээ нь e., 31.5/50mm or 22/40mm).
4. Торгуулийн менежмент & Эргэлтийн эргэлт: Integrated washing screens or sand classifiers remove deleterious fines, while oversize material is automatically recirculated for recrushing.

Хэрэглээний хамрах хүрээ: Хатуу чулуулгийн карьеруудад тохиромжтой (боржин чулуу, сагссах, шохойн чулуу) producing ballast for rail infrastructure, port construction, and heavyduty road base layers.
Хувьсгал: Not suitable for processing soft, highly abrasive ores or as a standalone solution without adequate upstream drilling/blasting and downstream logistics.

3. ҮНДСЭН ОНЦЛОГ

Hydroset CSS тохируулга | Техникийн үндэслэл: Hydraulic piston supporting the main shaft | Үйл ажиллагааны ашиг тус: Операторууд хаалттай талын тохиргоог тохируулах боломжтой (Css) for wear compensation or product size changes in under one minute without stopping the crusher. | ROI нөлөө: Тохируулгын зогсолтыг хүртэл бууруулна 80% гарын авлагын шилний системтэй харьцуулахад, increasing plant throughput availability.

Олон давхаргат бутлах камер | Техникийн үндэслэл: Optimized cavity profiles with varying crush zones (тэжээх, parallel zone) | Үйл ажиллагааны ашиг тус: Promotes interparticle rockonrock crushing in the upper chamber for reduced wear, and applies controlled pressure in the lower chamber for precise shaping. | ROI нөлөө: Produces up to 25% more cubicle end product while reducing manganese liner wear rates by an estimated 1530%.

Integrated Automation System (IAS) | Техникийн үндэслэл: PLCbased control with loadandlevel sensors | Үйл ажиллагааны ашиг тус: Monitors crusher power draw, хөндийн түвшин, and bearing pressures to optimize feed rate via variable frequency drives on conveyors, preventing overloads and chokefeeding. | ROI нөлөө: Maintains peak efficiency; field data shows consistent energy savings of 812% per ton crushed versus manual operation.

Төвлөрсөн тослох & Тосолгооны систем | Техникийн үндэслэл: Automated singlepoint lubrication unit with failsafe monitoring | Үйл ажиллагааны ашиг тус: Delivers precise grease volumes to all critical bearings on schedule; alerts operators to flow failures before damage occurs. | ROI нөлөө: Extends bearing service life by ensuring proper lubrication; eliminates manual greasing errors that cause premature failures.

Модульчлагдсан эд ангиудын загвар | Техникийн үндэслэл: Segmented liners and symmetrically designed wear parts | Үйл ажиллагааны ашиг тус: Liners can be rotated or replaced in sections. Common part numbers across similar crushers simplify inventory. | ROI нөлөө: Доторлогоо солих хугацааг ойролцоогоор багасгадаг 30% and lowers spare parts holding costs through inventory consolidation.

Хаалттай тээвэрлэлт & Dust Suppression Points | Техникийн үндэслэл: Fulllength conveyor covers and strategically placed misting nozzles at transfer points | Үйл ажиллагааны ашиг тус: Contains dust emissions at source without saturating material. | ROI нөлөө: Mitigates environmental noncompliance risks and reduces sitewide water usage for dust control by focusing suppression where it is most effective.

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандартын суурь | Advanced Quarry Ballast Plant Solution | Давуу тал (% Сайжруулалт) |
| : | : | : | : |
| Product Flakiness Index (FI) | FI >20% common in 2stage plants| FI consistently <15% via optimized VSI tertiary stage| ≥25% improvement in particle shape |
| Бутлуур доторлогооны амьдрал (Дунд) | ~500k tons per set in abrasive granite| ~650k tons per set with multilayer chamber design| ~30% extended service life |
| Төлөвлөсөн засвар үйлчилгээний зогсолт (Жилийн) | 1012 days for liner changes/mech service| Тооцоолсон 78 days with hydraulic adjustment & modular liners| ~35% reduction in planned downtime |
| System Energy Efficiency (кВт.ц/тн)~ 1" final product)| Өргөн хүрээтэй; -ийн суурь 2.8 кВт.ц/тн| Target of ≤2.4 kWh/ton with IAS optimization| Шалтгаална, хамаарна 15% reduction in energy consumption |
| Saleable Ballast Yield (% of feed)| ~6570% yield after washing out fines| Target yield of 7275% through precise crushing/screening| ~57% increase in premium product volume |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Дизайн хүчин чадлын хүрээ: -аас тохируулах боломжтой 200 дээр нь 600 metric tons per hour of finished ballast.
Эрчим хүчний шаардлага: Total installed plant power between 550 kw 1.2 МВт нь тохиргооноос хамаарна; primary voltage supply of 400V/50Hz or customized.
Материалын үзүүлэлтүүд: Хязгаарлагдмал шахалтын бат бэхийн зориулалтаар бүтээгдсэн (UCS) feed material up to 300 МПа. Constructed from abrasionresistant steel at critical wear points; main frames are heavyduty welded steel.
Физик хэмжээсүүд (Typical SemiMobile Setup): Ойролцоогоор 45 м талбайтай (Дээд) х 22м (Үнэр). Overall height restricted to <15m for ease of permitting.
Байгаль орчны үйл ажиллагааны хүрээ: Designed for ambient temperatures from 20°C to +45°C with optional coldweather packages available. Dust emissions designed to meet EU Stage V / equivalent standards with addon filtration.

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

Railway Infrastructure Project – Southeast Asia

Сорилт: A contractor needed guaranteed compliance with Network Rail Specification NR/SP/TRK/9039 for a major rail link project but faced variable basalt feed that caused frequent plugging in their existing cone crusher.
Хариу: Implementation of a tailored quarry ballast crushing plant featuring a largefeedopening primary jaw crusher followed by a cone crusher equipped with an automated clearing system and finishing VSI crusher.
Үр дүн: The plant achieved consistent production of Class B1 ballast at >280 TPH with zero unplanned stoppages due to packing over a sixmonth period—a key factor in meeting the project’s critical path schedule.

Granite Quarry Expansion – Northern Europe

Сорилт: A longestablished quarry’s aging twostage plant produced excessive fines (<22mm), limiting its saleable ballast yield while maintenance costs escalated sharply.
Хариу: Installation of a new tertiary crushing stage using a highspeed cone crusher dedicated solely to producing the final two topsize fractions required by their national railway authority’s specification EN13450 Type A.
Үр дүн: The modification increased total saleable ballast yield from an average of ~68% up towards an average yield exceeding >73%. This directly translated into an estimated additional €180k annual revenue at existing production volumes without increasing raw material extraction costs.

7. АРИЛЖААНЫ ХЭРЭГЛЭЭ

Our quarry ballast crushing solutions are offered across three primary tiers:

1.Standard Configuration Plant: Includes core jawconescreenVSI/screen modules on chassis/foundations with basic automation controls—ideal for operations seeking reliable performance improvement at capital cost efficiency.

2.HighAvailability Configuration: Adds features like automated setting regulation dual grease systems premiumtier bearings advanced predictive monitoring sensors—designed specifically around maximum uptime requirements found within fasttrack infrastructure projects where delays carry severe penalties

3.Fully Modular Mobile/SkidMounted System: Provides rapid deployment capabilities using preassembled skid units which connect via quickdisconnect couplings—suited towards shorterterm contracts remote locations requiring eventual relocation

Нэмэлт шинж чанарууд:
• Onboard diesel generator packs
• Advanced sound encapsulation cabins
• Highpressure water washing systems
• Remote telematics connectivity package

Үйлчилгээний багцууд:
Comprehensive support agreements cover scheduled maintenance parts supply including wear part consumption guarantees technical training programs emergency breakdown response times tailored according customer needs ranging from basic support through full operational management contracts

Санхүүжилтийн сонголтууд:
Flexible commercial structures available including outright purchase finance lease operating lease models—our team will work develop proposal aligns your cash flow project accounting requirements

Түгээмэл асуултууд

Q1 How does this plant handle variations in feed rock hardness within our quarry face?
The integrated automation system adjusts feeder rates based on realtime power draw preventing potential overloads during harder seams while maintaining optimal cavity levels during softer strata ensuring consistent product quality across varying conditions

Q2 What is typical installation commissioning timeline once equipment arrives onsite?
For semimobile assembly plants typical installation commissioning period ranges between four six weeks assuming prepared foundations electrical supply are ready Our project management team provides detailed schedule upfront coordinates directly your local contractors streamline process

Q3 Can existing conveyors screens be integrated into new primary secondary tertiary modules?
Yes integration possible often recommended reduce overall project cost thorough engineering review required ensure compatibility capacity loading structural adequacy our engineers conduct site audit provide integration feasibility report

Q4 What kind operator training provided ensure smooth handover?
We provide comprehensive training program covering normal operation startup/shutdown procedures routine maintenance troubleshooting Training conducted both our facility during factory acceptance test FAT then again onsite during commissioning phase Documentation includes detailed manuals video procedures

Q5 Are performance guarantees offered regarding throughput product shape specifications?
Yes we offer performance guarantees based upon agreed feed material characteristics laboratory testing Guarantees typically cover minimum throughput capacity maximum power consumption flakiness index These formalized within contract prior manufacturing commencement

Q6 How does pricing structure work optional features service packages?
Base pricing covers standard configuration as outlined brochure Optional features priced separately allowing customization Service packages typically structured annual cost based upon expected operating hours providing predictable budgeting maintenance expenses Detailed quotations clearly itemize all elements

Q7 What lead time expected from order placement delivery?
Lead times vary depending complexity specific configuration Current standard lead times range eight twelve months exworks Expedited options may available certain components discuss during quotation phase regular progress updates provided throughout manufacturing cycle