1. ABERTURA ACIONADA POR PAINPOINT

Are you managing recurring bottlenecks and hidden costs in your size reduction process? Distribuição inconsistente de tamanho de partícula, substituição de peças de desgaste excessivo, and unplanned downtime for maintenance are not just operational nuisances—they directly erode your profitability and throughput. Considere estes desafios comuns:
Alto custo operacional: Substituição frequente de martelos, telas, and liners due to premature wear, compounded by labor costs for changeovers.
Saída inconsistente: Variable feed materials lead to an inconsistent final grind size, compromising downstream process efficiency and product quality.
Tempo de inatividade excessivo: Longo, complex maintenance procedures for internal inspections and part replacements halt your entire production line.
Ineficiência Energética: Older or poorly designed hammer mills waste significant power on vibration, aquecer, and ineffective impact, rather than productive comminution.
Pó & Poluição Sonora: Inadequate sealing and damping create environmental and safety hazards, leading to potential compliance issues and worker discomfort.

Is your current equipment delivering predictable performance and total cost of ownership? The solution lies in selecting a hammer mill engineered not just to crush material, but to optimize your entire operational workflow.

2. VISÃO GERAL DO PRODUTO

Our industrial hammer mill is a heavyduty impact crusher designed for highvolume reduction of mediumhard to soft materials. It is a core component in aggregate production, pré-processamento mineral, limestone grinding for agricultural lime or flue gas desulfurization (FGD), e operações de reciclagem.

Fluxo de Trabalho Operacional:
1. Alimentação controlada: O material é introduzido através de um sistema de alimentação regulado (por exemplo, transportador de correia, alimentador vibratório) na câmara de moagem.
2. Impacto de alta velocidade: Um conjunto de rotor equipado com martelos rígidos ou de oscilação livre gira em alta velocidade, repeatedly striking the incoming material against breaker plates.
3. Classificação de tamanho: Crushed particles pass through a surrounding screen or grate; only material meeting the specified size exits the chamber.
4. Descarga & Transporte: Sized material is discharged via gravity or pneumatic system for further processing or stockpiling.

Escopo de aplicação & Limitações:
Ideal para: Calcário, gesso, carvão, agregados, recycled asphalt pavement (RAP), concreto de demolição, bark, and other friable materials.
Limitações: Não recomendado para materiais muito abrasivos (por exemplo, areia de sílica) sem opções específicas de liga, metais altamente dúcteis, or materials with high moisture content that may cause clogging without proper conditioning.

3. RECURSOS PRINCIPAIS

Sistema de rotor reversível | Base Técnica: O design simétrico do rotor permite a rotação final dos martelos | Benefício Operacional: Duplica a vida útil das bordas de ataque do martelo antes da substituição; reduces inventory by standardizing parts | Impacto do ROI: Cuts wear part costs by up to 40% over the lifecycle of the unit

Balanceamento Dinâmico | Base Técnica: Computeraided rotor balancing postassembly at operating RPM | Benefício Operacional: Minimiza a transmissão de vibrações aos rolamentos e à fundação; permite uma operação mais suave em alta velocidade | Impacto do ROI: Prolonga a vida útil do rolamento em média 30% and reduces structural fatigue

QuickAccess Clamshell Design | Base Técnica: Hinged housing sections secured by hydraulic rams or largebore bolts | Benefício Operacional: Full interior access for inspection, mudanças de tela, or hammer rotation in under 30 minutos | Impacto do ROI: Reduces standard maintenance downtime by approximately 70%, aumentando a produtividade anual

Revestimentos de desgaste segmentados | Base Técnica: Bolton liner plates manufactured from AR400 or chromium carbide alloys | Benefício Operacional: Individual sections can be replaced as needed without dismantling the entire mill housing | Impacto do ROI: Lowers liner replacement cost by targeting only worn areas; simplifies logistics

Air Assist & Integração de supressão de poeira | Base Técnica: Sealed housing with ports for negative pressure systems or controlled air flow | Benefício Operacional: Manages internal airflow to reduce heat buildup and directs fine particulates to collection systems | Impacto do ROI: Improves operational safety (reduces explosion risk), garante conformidade ambiental

Rolamentos autocompensadores de rolos para serviços pesados | Base Técnica: Oversized bearing housings with labyrinth seals and grease purge systems | Benefício Operacional: Handles high radial loads from unbalanced feed conditions; excludes contaminants | Impacto do ROI: Provides reliable service in highshock environments with extended lubrication intervals

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nossa solução para moinho de martelos | Vantagem documentada |
| : | : | : | : |
| Tonelagem por kWh (Limestone 6mm) | 8 10 Toneladas/kWh | 11 13 Toneladas/kWh| +2030% Eficiência Energética |
| Tempo de mudança de tela (Conjunto completo) | 4 6 Horas| 120k MTon| +50% Confiabilidade aprimorada |
| Nível de ruído em 1 Medidor (dBA) >100 dBA|<95 dBA with standard housing|<5 Redução de dBA |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Modelo dependente de 25 TPH acima 300 TPH on limestone (25mm feed to 3mm product).
Requisitos de energia: De 75 kW (100 HP) até 750 kW (1000 HP), configured for VSD control where applicable.
Diâmetro do rotor & Largura: From Ø800mm x 800mm up to Ø2000mm x 2500mm.
Materiais de Construção: Mainframe – Fabricated steel plate (min. 25milímetros). Hammers/Screens – Highcarbon steel/AR400/Chrome iron alloys optional. Liners – AR400 standard; ceramic composite optional.
Dimensões Físicas & Peso: Varia significativamente por modelo; largest units require planned foundation work (~1540 metric tons).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Dust ingress protection rating of IP54 standard.

6. CENÁRIOS DE APLICAÇÃO

Agricultural Lime Production Plant

Challenge A producer needed consistent fine grind (2milímetros) of limestone at 150 TPH but faced weekly downtime for screen changes and monthly hammer replacements due to abrasive silica content in the feedstock.

Solution Implementation of a heavyduty hammer mill featuring a reversible rotor with tungsten carbidetipped hammers and quickaccess clamshell doors.

Results Screen change time reduced from one full shift (8 horas) a menos de duas horas. Hammer life extended from ~10k tonnes to over 28k tonnes. Annual availability increased by an estimated 12%, achieving target throughput with one less scheduled maintenance day per month.

Construção & Instalação de reciclagem para demolição

Desafio Processamento misto C&D waste into clean aggregate was hampered by frequent jamming from noncrushables (rebar strands) causing severe rotor damage and belt slippage.

Solution Installation included a nonclogging steppedgrate screen design paired with shearbolt protected hammers on a lowinertia rotor that could be stopped quickly.

Results Incidents of catastrophic jamming dropped by over 90%. The shearbolt system protected the main shaft and bearings during overload events. Overall plant uptime improved significantly while reducing repair part expenditures by an estimated 35% anualmente.

7. CONSIDERAÇÕES COMERCIAIS

Nossos moinhos de martelo são oferecidos em três níveis principais:

1. Standard Duty Series For consistent feed materials requiring reliable performance at lower capital outlay.
2 Heavy Duty Series The core offering described here includes all major features like reversible rotors quickaccess design ideal for most mining aggregate applications
3 Extreme Duty Series Engineered for maximum abrasion resistance featuring specialized alloys automated lubrication systems advanced monitoring sensors

Optional Features Upgrades include programmable logic controller PLCbased monitoring packages automatic greasing systems explosion suppression systems custom discharge configurations

Service Packages Available options range from basic commissioning supervision through comprehensive multiyear planned maintenance agreements including guaranteed parts availability priority technical support

Financing Options We work with international export credit agencies project finance partners equipment leasing companies Flexible payment structures can be tailored including milestone payments upon delivery commissioning

8 Perguntas frequentes

Q What level of preparation is required for my feedstock before using this hammer mill
A For optimal performance feed should be prescreened to remove fines already at specification size Maximum feed size should not exceed 80% of the screen aperture opening Material moisture content should generally remain below 15% depending on clay content

Q How does this hammer mill integrate with my existing conveying dust collection systems
A Our engineering team provides detailed interface drawings specifying inlet outlet flange dimensions load points electrical requirements Standard units are designed for integration into both gravityfed pneumatic conveying circuits

P Qual é o prazo de entrega típico do comissionamento da colocação do pedido
A Lead times vary based on model specification For standard heavyduty models expect approximately 1620 weeks exworks including manufacturing testing documentation preparation Expedited production may be available subject inquiry

Q Can you provide wear part consumption estimates specific my material analysis
A Yes Based on your provided sample we conduct laboratory testing generate a detailed wear forecast outlining expected service life hammers screens liners under defined operating conditions This forms basis our guaranteed performance agreements

P Que treinamento foi oferecido à nossa equipe de manutenção operacional
A Comprehensive training included covers safe operation routine maintenance troubleshooting procedures conducted both our facility during onsite commissioning We provide detailed operation manuals parts lists instructional videos