1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing a quarry ballast operation where inconsistent product shape, penjanaan denda yang berlebihan, dan penyelenggaraan yang tidak dirancang akan menghakis margin anda? Pengeluaran balast kereta api berspesifikasi tinggi memerlukan ketepatan, yet many crushing plants struggle with these persistent challenges:
Kos Pakai Tinggi: Granit yang kasar, basalt, or gneiss rapidly degrades crusher liners and wear parts, leading to frequent stoppages and unpredictable consumables expenditure.
Poor Cubicity & Excessive Fines: Inefficient crushing action produces flaky or elongated aggregates and an oversupply of unsaleable fines (5mm), failing to meet stringent EN 13450 or AREMA gradation standards for angularity and durability.
Kesesakan Kapasiti & Inefficiency: An illmatched primarytosecondary crushing circuit creates choke points, mengehadkan jumlah pengeluaran loji dan meninggalkan potensi hasil tidak diterokai.
Kerumitan Operasi yang Tinggi: Equipment requiring constant adjustment and monitoring increases the skill burden on your team and raises the risk of offspec production runs.

What if your ballast crushing line could deliver consistent, inspec product with lower cost per tonne, extended maintenance intervals, dan kawalan yang dipermudahkan? Penyelesaiannya terletak pada pemilihan peralatan penghancur balast kuari yang direka khas.

2. GAMBARAN KESELURUHAN PRODUK

Our quarry ballast crushing equipment comprises heavyduty, stationary or semimobile crushing plants engineered specifically for highvolume production of railway ballast. The operational workflow is optimized for shape and yield:

1. Pengurangan utama: Dumpfed material is initially reduced by a robust jaw crusher or gyratory crusher to a manageable size (biasanya <250mm).
2. Secondary Shape Crushing: The core of ballast production. Prescreened feed is directed to a cone crusher configured for aggressive interparticle comminution in a crowded chamber.
3. Saiz Akhir & Pemeriksaan: Crushed aggregate is precisely screened on heavyduty vibrating screens. Bahan onspec (mis., 31.563mm) is conveyed to stockpile; oversize is recirculated; undersize is diverted for byproduct sales or waste.

Skop Permohonan: Sesuai untuk batu keras (UCS >150 MPa) quarries supplying national rail networks, private industrial sidings, and construction projects requiring premium aggregate. This equipment is designed for continuous, operasi hightonnage.

Batasan: Not suitable for soft or highly abrasive sedimentary rock without specific liner material review. Maximum feed size and ultimate capacity are determined by model selection.

3. CIRI TERAS

Pelarasan CSS Hydroset | Asas Teknikal: Hydraulic cavity clearing and closedside setting control | Faedah Operasi: Operators can adjust product gradation or clear blockages in under 60 seconds from a central location, minimizing downtime during changeovers or unexpected events. | Kesan ROI: Reduces noncrushing time by up to 70% compared to manual adjustment systems, terus meningkatkan daya pengeluaran tahunan.

Sistem Pengoptimuman Hayat Pelapik | Asas Teknikal: Automated wear compensation via constant hydraulic pressure on the crushing mantle | Faedah Operasi: Maintains consistent product gradation as liners wear without manual intervention, ensuring continuous spec compliance over longer campaigns. | Kesan ROI: Extracts maximum usable life from wear parts and reduces the frequency of liner changes, lowering both part costs and labor hours.

Ruang Penghancur Berbilang Lapisan | Asas Teknikal: Engineered cavity profiles that promote interparticle crushing within a packed bed of material | Faedah Operasi: Forces rockonrock breakage in the secondary/tertiary stage, producing superior particle cubicity while reducing direct metalonrock wear and fines generation. | Kesan ROI: Meningkatkan hasil balast yang boleh dijual sebanyak 815% per tonne of feed rock while decreasing liner abrasion costs.

HeavyDuty Vibrating Screen Integration | Asas Teknikal: HighG force screening decks with precisely sized apertures mounted on reinforced frames | Faedah Operasi: Provides accurate final separation even under wet or sticky conditions, ensuring final product is free of undersized material as per rail authority specifications. | Kesan ROI: Eliminates costly reprocessing of contaminated stockpiles and prevents rejection of loads at the point of delivery.

Automasi PLC Berpusat | Asas Teknikal: Programmable Logic Controller managing crusher load, kadar makanan, and interlocks with plant conveyors | Faedah Operasi: Allows a single operator to monitor and optimize the entire circuit from a control room, regulating power draw for peak efficiency. | Kesan ROI: Lowers personnel requirements per shift and reduces energy consumption per tonne by optimizing motor load.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Penyelesaian Penghancur Balast Kuari Kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Kehidupan Pelapik (Batu Abrasive)| 450550 kTonnes| 600750 kTonnes| +25% ke +35% |
| Saleable Yield (>95% Sifat kubisiti)| ~82% of feed| 8892% daripada suapan| +7% ke +12% |
| Penggunaan Tenaga Khusus| ~0.85 kWh/Tonne| ~0.72 kWh/Tonne| 15% |
| Average Unplanned Stoppages| 1218 jam/bulan| <6 jam/bulan| 60% |
| Ketekalan Penggredan (Std Dev)| High variability within spec band| Tight control within spec band (field data shows ±3mm)| Improved process stability |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 200 ke atas 1,200 tan sejam (tph) of finished ballast product.
Keperluan kuasa: Primary circuit from 90 kw; Secondary/Tertiary cone crushers from 160 kW sehingga 500 kW bergantung kepada saiz model.
Spesifikasi Bahan: Engineered for maximum feed size up to 800mm; produces standard railway ballast fractions (mis., 31.5/50mm, 40/70mm). Crusher mantles/bowls available in Manganese steel grades or optional premium alloys for extended life.
Dimensi Fizikal (Stesen Menengah Biasa): Lebih kurang. Panjang: 10m x Lebar: 5m x Tinggi: 5m (excludes feed hopper/discharge conveyors).
Julat Operasi Persekitaran: Designed for ambient temperatures from 20°C to +45°C with optional heating/cooling systems for lubrication units.

6. SENARIO APLIKASI

Projek Infrastruktur Rel Negara | Cabaran: A contractor required guaranteed daily tonnage of EN13450 Type A ballast under a fixedprice contract with severe penalties for delay. Their existing plant produced excessive fines (~22%) causing yield shortfalls.| Penyelesaian: Implementation of a tailored quarry ballast crushing circuit featuring our multilayer cone crusher technology paired with precise screening.| Keputusan: Achieved consistent yield of saleable ballast at >90%, with fines generation reduced to below 14%. The project met all delivery schedules without penalty.

Pengembangan Kuari Granit | Cabaran: A quarry operator needed to double ballast output without expanding their primary footprint or significantly increasing shift labor costs.| Penyelesaian: Installation of a highcapacity secondary/tertiary modular crushing station designed for direct conveyor integration with their existing primary crusher.| Keputusan: Daya pengeluaran loji meningkat sebanyak 115%. The automated system allowed operation with one additional operator per shift instead of two, improving output per labor hour by over 90%.

7. PERTIMBANGAN KOMERSIL

Our quarry ballast crushing equipment is offered in three primary tiers:

1. Konfigurasi Tugas Standard: Untuk operasi <400 tph with robust base specifications.
2. Konfigurasi Kapasiti Tinggi: For outputs >600 tph featuring heavyduty components and advanced automation.
3. Modular/SkidMounted Configuration: For operations requiring future relocation or phased capital expenditure.

Optional features include dust suppression systems automated grease lubrication systems remote monitoring telematics packages

We offer comprehensive service packages including scheduled maintenance programs parts supply agreements

Financing options include capital purchase leasetoown agreements

8.Soalan Lazim

Q1 Is your equipment compatible with our existing primary jaw crusher
Yes our secondary stations are designed as standalone modules They can be integrated via conveyor systems

Q2 What impact will this have on our overall plant power consumption
Field data shows that due to optimized load management total specific energy consumption often decreases despite increased throughput

Q3 How long does commissioning typically take
For a complete turnkey station expect four weeks For modular integration into an existing line typical commissioning takes ten working days

Q4 What are the commercial terms
We require an order deposit upon contract signing Balance payment follows agreed milestones such as factory acceptance shipping confirmation

Q5 Do you provide operational training
Yes we include comprehensive training at your site during commissioning covering operation routine maintenance troubleshooting