HPA4000 HeavyDuty Hammer Mill | Engineered for Uninterrupted Mineral Reduction

1. PEMBUKAAN PAINPOINT DRIVEN

Adakah peningkatan kos operasi dan masa henti yang tidak dirancang menghakis margin pemprosesan mineral anda? Plant managers and engineering contractors consistently face three critical challenges in size reduction operations:

Masa Henti Berlebihan untuk Penyelenggaraan: Frequent wear part replacement halts your entire crushing circuit. Industry data indicates that standard hammer mills can require liner and hammer changes every 400600 hours in abrasive applications, kos lebih 50 hours of annual production time per unit.
Penggredan Output Tidak Selaras: Fluctuations in feed material hardness or moisture content lead to an offspec product, causing bottlenecks in downstream processes and potential rejections.
Unscheduled Bearing Failures: Contamination ingress and imbalanced rotor assemblies cause catastrophic bearing failures, resulting in repair costs exceeding $15,000 and multiday production stoppages.

Bagaimana anda mencapai daya pengeluaran yang konsisten, mengurangkan jumlah kos pemilikan, and protect your operation from costly interruptions? The solution requires a hammer mill engineered not just to process material, but to withstand the demands of continuous industrial service.

2. GAMBARAN KESELURUHAN PRODUK

The HPA4000 is a heavyduty, industrial hammer mill designed for primary, sekunder, or tertiary reduction of mediumhard to hard minerals such as limestone, Gypsum, arang batu, and phosphate rock. Its design prioritizes durability and controlled fragmentation for aggregate production, mining preprocessing, dan penyediaan mineral industri.

Aliran Kerja Operasi:
1. Suapan Terkawal: Material is introduced via a regulated feed conveyor into the mill’s reinforced feed chute.
2. Pengurangan Kesan: A highinertia rotor assembly with dynamically balanced hammers accelerates material into the manganese steel breaker plates.
3. Klasifikasi saiz: Processed material passes through a heavyduty grate screen; particles meeting spec exit, manakala bahan bersaiz besar dikekalkan untuk pengurangan selanjutnya.
4. Pelepasan & Pengangkutan: Sized material is discharged for conveyance to the next stage in your processing circuit.

Skop Permohonan & Batasan:
Sesuai Untuk: Mediumhard materials (hingga 8 Mohs), dry or slightly moist feeds requiring top sizes from 50mm down to 3mm.
Tidak Disyorkan Untuk: Ultraabrasive materials like silica sand without specific liner configurations, highly sticky or claybound feeds without prescreening, or applications requiring submillimeter pulverization.

3. CIRI TERAS

Sistem Rotor Boleh Balik | Asas Teknikal: Symmetrical rotor design with hardfaced hammer mounting points | Faedah Operasi: When the leading edges of hammers wear, operators can reverse the rotor direction or flip hammers to utilize a second cutting edge without disassembly downtime | Kesan ROI: Doubles service intervals for hammer sets, reducing parts consumption by up to 40% setiap tahun.

Plat Pemecah Bersegmen & Grates | Asas Teknikal: Individual highchrome cast alloy sections secured with captive bolts | Faedah Operasi: Worn sections can be replaced individually in under two hours instead of replacing an entire liner assembly | Kesan ROI: Mengurangkan masa henti penggantian pelapik sebanyak 70% and reduces consumable inventory costs.

Meterai Labirin & AirPurge Bearing System | Asas Teknikal: Multistage dust exclusion seals supported by a regulated air purge | Faedah Operasi: Creates positive pressure to prevent abrasive dust ingress into main rotor bearings | Kesan ROI: Extends bearing service life by a documented minimum of 300%, eliminating unscheduled bearing failures.

Pengimbangan Dinamik & Pad Pemantauan Getaran | Asas Teknikal: Factorybalanced rotor with integrated sensor mounting points on the housing | Faedah Operasi: Allows for routine vibration trend monitoring; enables predictive maintenance scheduling before imbalance causes damage | Kesan ROI: Prevents cascading component failures, protecting against an average of $25k in unexpected repair costs.

Pintu Penyelenggaraan QuickAccess | Asas Teknikal: Hydraulicallyassisted side and top doors with integrated safety interlocks | Faedah Operasi: Menyediakan akses penuh ke ruang pengisaran untuk pemeriksaan, perubahan skrin, or cleanup in minutes without overhead crane dependency | Kesan ROI: Reduces standard maintenance window duration by over 60%, returning the mill to production faster.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Purata pesaing) | HPA4000 Hammer Mill Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Hayat Perkhidmatan Bahagian Pakai (Bijih Pelelas) | 550 Waktu Operasi | 850 Waktu Operasi | +55% Lebih Panjang Umur |
| Perubahan Skrin Masa Buruh (2kru orang) | 4.5 Jam | 1.75 Jam | 61% Less Downtime |
| Penggunaan Tenaga Khusus (kWj/tan) Didokumenkan| ~1.8 kWh/ton @ 10mm output| ~1.65 kWh/ton @ 10mm output| 8.3% Penggunaan Tenaga Lebih Rendah |
| Annual Bearing Replacement Rate (24/7 Op.)| >1.0 per year per mill| <0.33 per year per mill| 67% Fewer Replacements |

5. SPESIFIKASI TEKNIKAL

Penilaian Kapasiti: 120 180 Tph (dependent on feed material and target output size)
Keperluan kuasa: Motor Pemacu Utama: 400 kw (500 Hp), WEG Premium Efficiency IE3
Perhimpunan Rotor: Diameter: 1500mm; Lebar: 2000mm; Kelajuan: ~750 RPM
Spesifikasi Bahan: Housing – Fabricated AR400 Steel; Hammers – Forged Alloy Steel with Tungsten Carbide Tips (Standard); Plat Pemutus / Grates – HiChrome Alloy Castings
Dimensi Fizikal (L x W x H): Lebih kurang. 3m x 2m x 2m
Julat Operasi Persekitaran: Julat Suhu Ambien (20°C hingga +45°C); Dusttight construction rated up to IP65

6. SENARIO APLIKASI

Loji Pengeluaran Agregat – Pemprosesan Batu Kapur

Challenge A quarry operation experienced premature failure of standard hammers every three weeks when processing abrasive silicacontaminated limestone belts.
Solution Implementation of two HPA4000 hammer mills configured with tungsten carbidetipped reversible hammers.
Results Wear part life extended to seven weeks per set; annual consumable costs reduced by $42k per mill; plant achieved scheduled maintenance alignment with other circuit components.

Industrial Mineral Processing – Gypsum Preparation

Challenge Inconsistent moisture content in feedstock caused frequent clogging of discharge grates in an existing mill system.
Solution The HPA4000 was installed with an optional internal breaker plate heating system and larger openarea grate design.
Results Clogging incidents reduced from weekly occurrences to fewer than four per year; plant throughput stabilized at design capacity of 150 TPH regardless of seasonal feedstock variations.

7. PERTIMBANGAN KOMERSIL

The HPA4000 hammer mill is offered as a complete package including motor drives,Vbelts,and starter equipment on a common base frame.

Peringkat Harga & Pilihan
Konfigurasi Pangkalan (HPA4000STD): Includes standard alloy hammers and manganese liners.
Pakej HighAbrasion (HPA4000HA): Upgraded tungsten carbidetipped hammers and chrome alloy liners (~+18% investment).
Automation Ready Package (HPA4000AR): Includes vibration sensors,kuar suhu,and integration wiring for plant SCADA systems (~+12% investment).

Pakej Perkhidmatan:
1tahun / 2000hour comprehensive parts & labor warranty included.Factorysupported annual inspection contracts available.Extended wearpart supply agreements offer guaranteed pricing.

Financing options include capital lease agreements tailored for municipal contractors,mine development projects,and private aggregate producers seeking predictable monthly expenditure models over 36, 60, or 84month terms.Equipment tradein programs are evaluated casebycase

8. Soalan Lazim

Q What are the primary factors that determine throughput capacity?
A Capacity is dictated by feed material bulk density,Bond Work Index hardness,and target output size.A detailed lab analysis of your sample determines precise tonnage ratings

Q Is this hammer mill compatible with our existing PLC control system?
A Yes.The HPA4000 control panel includes standard Modbus TCP/IP protocol outputs.All critical operational data can be integrated into most modern plant control rooms

S Apakah jangkaan masa utama dari penempatan pesanan?
A Standard configuration units ship within 14 weeks.Custom configurations may require additional engineering time which will be specified during project quotation

Q How does this design address operator safety?
A The unit exceeds CE standards featuring zeromotion electrical interlocks on all access doors ensuring the rotor cannot be energized during inspection Hydraulic door assists eliminate manual handling risks

Q Adakah jaminan prestasi disediakan?
A Yes.Based on certified lab analysis of your provided feedstock we guarantee final product gradation curves within +/5%and specific energy consumption figures as quoted