1. ABERTURA ACIONADA POR PAINPOINT

Managing the cost and efficiency of primary size reduction is a persistent challenge in limestone quarrying and processing. Feed inconsistente, material abrasivo, e o tempo de inatividade não planejado prejudica diretamente suas margens de lucro. Are you facing these specific operational hurdles?

High Cost of Comminution: Crushing is the single most energyintensive stage in your plant. Inefficient equipment can increase your costperton by 1525% through excessive power draw and premature wear part consumption.
Tempo de inatividade não planejado para manutenção: The abrasive nature of limestone accelerates wear on crusher components. Freqüente, lengthy shutdowns to replace liners, martelos, or jaws halt your entire production line, custando milhares por hora em perda de produção.
Inconsistência na qualidade do produto: Fluctuations in feed size or moisture content can lead to offspec product from your primary crusher, causing bottlenecks and recrushing in secondary stages, reducing overall system yield.
Rigidez para variações de alimentação: Many primary crushers struggle with slabby material or occasional oversize rock from the blast face, leading to blockages that require dangerous manual clearing and further downtime.

What if your primary crushing station could deliver more predictable operating costs, extend intervals between maintenance, and produce a more consistent feed for your downstream circuits?

2. VISÃO GERAL DO PRODUTO

O [Nome da sua empresa] Triturador de impacto primário is engineered as a heavyduty, rotorbased machine for highvolume reduction of quarried limestone. It is designed to accept large feed rock (up to 60”) from the face and reduce it to a conveyable size for secondary processing in a single stage.

Fluxo de Trabalho Operacional:
1. Quarryrun limestone is fed via dump truck or wheel loader into the crusher’s large feed opening.
2. Material enters the robust rotor assembly, where massive hammers or blow bars accelerate it against stationary anvils or breaker plates.
3. Repeated impact fractures the rock along its natural cleavage planes.
4. Crushed material exits through an adjustable grate or apron setting, which controls the top product size.
5. Product is discharged onto a conveyor belt for transport to the next stage of processing.

Escopo de aplicação & Limitações:
Ideal para: Hightonnage quarry primary crushing of lowabrasive to moderately abrasive limestone; operations requiring high reduction ratios (até 20:1) em uma única passagem; handling material with occasional clay or moisture content.
Limitações: Not recommended for highly abrasive silicarich stone or granite as primary wear costs may become prohibitive. Requires consistent feed control for optimal performance and longevity.

3. RECURSOS PRINCIPAIS

Sistema de Ajuste Hidráulico | Base Técnica: Cilindros hidráulicos controlados por computador | Benefício Operacional: Allows operators to adjust the crusher gap setting (CSS) or open the housing for clearing in minutes from a remote location, without manual labor. | Impacto do ROI: Reduces adjustment and clearing downtime by up to 80%, aumentando a disponibilidade operacional anual.

Projeto de rotor monocorpo | Base Técnica: Solid steel rotor disc with weldedon locking pieces for blow bars | Benefício Operacional: Provides exceptional inertia for crushing large slabs and high mass throw for better reduction. Eliminates stress points found in segmented rotors. | Impacto do ROI: Os dados de campo mostram um 3040% increase in service life over multipiece rotors under similar conditions, adiando grandes custos de reconstrução de capital.

Sistema de peças de desgaste QuickChange | Base Técnica: Wedgelocked blow bars and breaker plates with accessible tooling points | Benefício Operacional: Your maintenance crew can reverse or replace all wear parts from outside the crusher using standard tools, significantly reducing liner changeout time. | Impacto do ROI: Cuts planned maintenance windows by over 50%, translating directly into hundreds of additional production hours annually.

Alimentador de avental para serviço pesado & Scalper Option | Base Técnica: Alimentador vibratório integrado para ursos pardos (VGF VGF) with independent drive | Benefício Operacional: Remove multas (6”) from the crusher feed prior to entry, reducing unnecessary wear and power consumption while boosting capacity on sticky material.| Impacto do ROI: Improves overall system throughput by 1525% enquanto reduz o consumo específico de energia (kWh/tonelada).

Unidade Avançada & Sistema de proteção de cinto | Base Técnica: Direct Vbelt drive from highefficiency TEFC motors with fully enclosed guards| Benefício Operacional: Maximizes power transmission efficiency (>96%) while ensuring operator safety and compliance with MSHA/OSHA regulations.| Impacto do ROI: Reduces energy loss compared to indirect drives; eliminates risk of costly violations and injuryrelated stoppages.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Mandíbula/Giratório) | Our Primary Impact Crusher Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Taxa de redução (Single Pass) | 6:1 8:1 (Mandíbula), 5:1 8:1 (Giratório) | Até 20:1 | +150% vs Jaw |
| Tempo de troca da peça de desgaste| 1624 horas (Mandíbula morre) / 48+ horas (Gyratory concaves) | <8 horas (full set blow bars) | Até 67% mais rápido |
| Tolerance for Clay & Umidade| Low High risk of packing & sufocando| High Open discharge design handles moderate moisture without clogging| Significant operational flexibility |
| Consumo Específico de Energia| Linha de base (Maldito Mandíbula) | Até 15% lower kWh/ton on comparable limestone| Direct reduction in operating cost |
| Barulho & Geração de poeira| High mechanical noise & dust at nip point| Lower mechanical noise; optional integrated water spray system available| Improved worksite environment |

5. ESPECIFICAÇÕES TÉCNICAS

Designação do modelo: PI1615
Faixa de capacidade: 500 900 TPH (dependent on feed gradation and product size)
Abertura de alimentação: 72” x 60” (1830mm x1520mm)
Tamanho máximo de alimentação: Up to 60” (1524milímetros) cube
Rotor Diameter x Width:63” x60” (1600mm x1515mm)
Requisitos de energia da unidade:600 HP(450 kW), TEFC electric motor
Approximate Operating Weight:120,000 libras(54,400 kg)
Key Wear Parts Material: Martensitic Chrome Steel Blow Bars; Manganese Steel Breaker Plates
Faixa operacional ambiental: Ambient temperatures from 20°Fto +120°F(29°Cto +49°C); dustand weatherprotected bearings.

6. CENÁRIOS DE APLICAÇÃO

Midwest Aggregate Producer – HighSilica Limestone Quarry

Desafio: A major producer faced excessive wear on jaw crusher manganese dies every 6 weeks due to high quartz content in their limestone seam, causing recurring downtime and unpredictable cost spikes.
Solução: Implementation of our Primary Impact Crusher configured with specialized highchrome martensitic blow bars designed for abrasion resistance.
Resultados: Wear life extended to an average of14 weeksbetween changes—a133% improvement.Downtime events were cut by more than half,and consumable costperton was reduced by28%.

Integrated Cement Plant – Direct Feed to Raw Mill

Desafio: The plant’s old gyratory crusher could not handle variations in quarry moisture without frequent bridging.The resulting inconsistent feed size disrupted raw mill optimization.
Solução: A turnkey installation replacing the gyratory with our Primary Impact Crusher equipped with an integral apron scalper.
Resultados: The scalper removed problematic fines,and the impactor’s open design eliminated bridging.Product consistency improved,variationin raw mill feed size was reduced by70%,andmill throughput increased by12%.

Large Road Base Producer – SinglePass Crushing

Desafio: Producing specification road base required primary e secondary crushing stages,increasing capital footprint,custos de combustível,and manpower.
Solução: Deployment of a largecapacity Primary Impact Crusher set with a closedside apertureto produce a wellgraded0”4”productin one pass.
Resultados:The twostage circuit was consolidated into one.Reduced equipment count lowered fuel consumption by22%,and labor requirements were streamlined,increasing net profit per tonby18%.

Considerações Comerciais

Our Primary Impact Crushers are offered across three capability tiers:

1.Nível de serviço padrão(Models PI1010toPI1313): Para menor tonelagem (<400TPH) operations.Pricing typically rangesfrom$250K$450K USD.Base configuration includes standard rotor,civil drawing package,e controles básicos.

2.Nível de serviço pesado(Models PI1415toPI1620): For mainstream quarry applications(400–1000TPH).Pricing typically rangesfrom$500K$900K USD.Includes features like hydraulic adjustment,martensitic starter blow bar set,and advanced bearing monitoring.

3.Camada de planta modular(Fully SkidMounted Systems): Includescrusher,VGFfeeder,transportador para viagem,and walkways.Pricing starts at$1.M USD.Designedfor rapid deploymentwith minimal civil works.

Recursos opcionais incluem:
Automated Gap Control(AGC)sistema
Thirdgeneration composite ceramicwear linersfor ultraabrasive applications
Dust suppression/waterspray ring package
Pacote telemático de monitoramento remoto

Oferecemos contratos de serviços abrangentes que cobrem manutenção programada,inspeções,andwear part supply at predictable fixed rates.Financing options includeoperating leases,arrendamentos de capital,e financiamento específico do projeto através dos nossos parceiros,directly aligning payment scheduleswith your production cash flow.

Perguntas frequentes

P:What downstream equipment is this crusher compatible with?
UM:The Primary Impact Crusherexcels at creatinga wellfractured,cubical product idealfor feeding cone crushersor horizontal shaft impactorsin secondary positions.It integrateswith all standard conveyingand screening systems.

P:What is therealistic expectedwear part lifein hard limestone?
UM:Lifedepends on abrasiveness(free silica content).Industry testing demonstratesblow bar life rangingfrom80，000to200，000tonsin typical commercial limestonematerial.Specific projectionsare provided during application review.

P:Canyou handlethe oversizefromour blasting which sometimesexceedsyour statedmax feedsize?
UM:The robustrotorandhydraulic opening systemare designedto handle occasional oversize.The keyis properfeed controlatthe face.We recommend pairingthecrusherwithour optionalheavyduty apron feederfor best resultsin such conditions.

P:What arethe lead timesfor majorwear components?
UM：We maintainstrategic stockof commonblow barandbreaker plate setsfor our HeavyDuty tier modelsin regional warehouses，targetingshipmentwithin72hoursfor emergency ordersunder service agreements。

P：How doestheoperatingcostcomparetoajawcrusheroverfiveyears？
UM：TotalCostofOwnership(TCO）analysesconsistentlyshowalowerTCOforthePrimaryImpactCrusherafieryearsdespitehigherinitialwearpartcost。Thesavingsarederivedfromlowerenergyconsumption（－15％），reduceddowntime（－40％），andhigheryieldofinspecproduct。ArepresentativeTCOmodelforyouroperationcanbeprovided。

P：Whatlevelof foundationisrequired？
UM：Asastandalonemachine，itrequiresasubstantialreinforcedconcretefoundation。Ourengineeringpackageincludesfullloaddynamicfoundationdrawingsforyourcivilcontractor。Themodularskid－mountedplantoptiondrasticallyreducesthiscivilrequirement。

P：Areoperator trainingandsupport included？
UM：Sim。Purchaseincludesacomprehensiveonsite trainingprogramforyouroperatorsandmaintenanceteamon safeoperation，verificações diárias，andbasic troubleshooting。Additionally，24／7technicalphone supportisprovided。