1. ABERTURA ACIONADA POR PAINPOINT

Are inconsistent feed materials and rising operational costs impacting your mineral processing or aggregate production line? Inefficient size reduction directly translates to lost revenue through excessive energy consumption, substituição prematura de peças de desgaste, e tempo de inatividade não planejado. Considere estes desafios comuns:
Alto custo operacional: Oversized motors and inefficient grinding mechanics lead to unsustainable power draw per ton of processed material.
Tempo de inatividade excessivo para manutenção: Frequent hammer replacement and rotor servicing halt your entire crushing circuit, creating costly bottlenecks.
Gradação inconsistente do produto: Uncontrolled particle size distribution fails to meet downstream process requirements, reducing final product quality and value.
Unplanned Component Failure: Inferior materials in critical components like rotors, rolamentos, and liners result in catastrophic failures.

How can you achieve a consistent, specgrade output while controlling the total cost of ownership? The solution requires a hammer mill engineered not just for power, mas para precisão, durabilidade, and operational economy.

2. VISÃO GERAL DO PRODUTO

The ODM Harga Hammer Mill is a heavyduty industrial impact crusher designed for primary, secundário, ou redução terciária de materiais semiduros a duros. Its operation is based on a highkineticenergy impact principle.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Material is fed via vibratory feeder or conveyor into the mill’s robust feed hopper.
2. Redução de tamanho: Material is struck by rapidly rotating hammers (mounted on a forged rotor), fragmenting it upon impact against the adjustable breaker plates.
3. Classificação & Descarga: Crushed material passes through a screen grate of specified aperture size; saída de partículas de tamanho correto, enquanto peças grandes são retidas para maior impacto.

Escopo de aplicação: Ideal para calcário, gesso, carvão, agregados, concreto de demolição, e certos minerais industriais.
Principais limitações: Não é adequado para materiais altamente abrasivos (por exemplo, areia de sílica) sem opções específicas de liga, ou para pegajoso, clayrich feeds that may cause screen clogging.

3. RECURSOS PRINCIPAIS

Balanceamento Dinâmico do Rotor | Base Técnica: Balanceamento dinâmico auxiliado por computador em RPM operacional | Benefício Operacional: Elimina vibrações destrutivas, prolonga a vida útil do rolamento em mais 40% | Impacto do ROI: Reduces structural stress and maintenance intervals, lowering longterm repair costs.

Reversible Hammer System | Base Técnica: Symmetrical hammer design with multiple wear edges | Benefício Operacional: Operators can reverse or rotate hammers to utilize all wear edges before changeout | Impacto do ROI: Increases service life of hammer sets by up to 100%, reducing part inventory frequency.

Tela Modular & Breaker Plate Design | Base Técnica: Segmented wear plates and quickchange screen cartridges | Benefício Operacional: Change screen size or replace worn liners in under 2 horas versus. industry average of 46 | Impacto do ROI: Minimizes downtime during product changeovers or maintenance.

Conjunto de rolamento para serviços pesados | Base Técnica: Oversized spherical roller bearings with labyrinth seals and grease purging system | Benefício Operacional: Withstands shock loads and prevents contaminant ingress in highdust environments | Impacto do ROI: Field data shows bearingrelated failures reduced by over 60% across a 5year period.

Sistema de acoplamento de acionamento direto | Base Técnica: Flexible coupling connecting motor directly to rotor shaft | Benefício Operacional: Elimina perdas e manutenção da correia em V; transmits power at >98% eficiência | Impacto do ROI: Reduz o consumo de energia em aproximadamente 57% em comparação com sistemas tradicionais acionados por correia.

Smart Access & Safety Design | Base Técnica: Hydraulically assisted hinged housing with mechanical safety locks | Benefício Operacional: Enables fast, safe access to crushing chamber for inspection and service without full disassembly | Impacto do ROI: Improves operator safety and reduces service labor hours by an estimated 30%.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | ODM Harga Hammer Mill Solution | Vantagem documentada |
| : | : | : | : |
| Tonelagem por kWh (Calcário) | 8 10 Toneladas/kWh (for comparable duty) | 11 13 Toneladas/kWh (dependente do site)| +15% para +25% Ganho de eficiência |
| Tempo médio entre falhas (Rolamentos Críticos) | ~3,500 4,500 horas| >7,000 horas (com protocolo recomendado)| +60% Service Life Improvement |
| Tempo de troca de tela (Conjunto completo) | Média 46 horas| <2 hours with trained crew| ~60% Downtime Reduction |
| Utilização de peças de desgaste (Martelos)| Singleuse or twoedge design| Four usable edges via rotation/reversal| Até +100% Utilização |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Modelos disponíveis em 50 TPH acima 400 Capacidade de transferência de TPH (depende do tipo de material & tamanho do produto).
Requisitos de energia: Classificações do motor de 200 kW até 1250 kW. Tensão conforme especificação do cliente (por exemplo, 380V/415V/6.6kV).
Especificações de materiais:
Rotor: Forged steel shaft with cast steel discs.
Martelos/placas rompedoras: Ferro fundido de alto cromo (HRC ≥58) padrão; Manganese steel or tungsten carbide options available.
Housing/Casing: Fabricated from heavyduty steel plate with replaceable AR400 liner plates.
Dimensões Físicas: Varia de acordo com o modelo; typical footprint ranges from ~25m² to ~60m² including motor baseplate.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Dusttight construction meets IP54 ingress protection standards.

6. CENÁRIOS DE APLICAÇÃO

Aggregate Plant – Basalt Crushing

Challenge A quarry needed consistent 25mm aggregate but faced weekly downtime due to premature hammer wear in their existing mill.
Solution Implementation of an ODM Harga Hammer Mill equipped with tungsten carbidetipped hammers and the quickchange screen system.
Results Achieved consistent product gradation with hammer set life extended from ~10 days to ~45 days. Annual maintenance downtime reduced by an estimated 300 horas.

Planta de Cimento – Pré-Britagem de Calcário

Challenge High energy costs per ton crushed were eroding plant margins; vibration issues also caused ancillary structural damage.
Solution Installation of a dynamically balanced ODM Harga model with direct drive coupling.
Results Specific power consumption improved by 18%. Measured vibration levels remained below ISO standards for two years postinstallation.

7. CONSIDERAÇÕES COMERCIAIS

Pricing is structured according to capacity class:
Série de serviço padrão (<150 TPH): Base configuration focused on core reliability for smaller operations.
Série para serviços pesados (150300 TPH): Enhanced features standard including reversible hammers and hydraulic access systems—the most common tier for midsize plants.
Extra Heavy Duty Series (>300 TPH):) Fully customized solutions with premium alloy options and advanced monitoring systems.

Recursos opcionais incluem:
PLCbased automation packages
Sensores de monitoramento de condição on-line
Special alloy wear packages
Custom feed chutes

Service packages range from basic commissioning support up to comprehensive annual maintenance contracts that guarantee parts availability within specified lead times. Financing options are available through partner institutions covering equipment leasing or purchase plans tailored over a period of time.

8. Perguntas frequentes

Q1 Is the ODM Harga Hammer Mill compatible with my existing crushing circuit?
A1 The mill can be engineered to interface with most standard conveyor sizes and plant layouts provided feed size specifications are met; our engineering team reviews your P&ID diagrams as part of the presale assessment.

Q2 What is the expected impact on my plant's overall energy consumption?
A2 Industry testing demonstrates reductions in specific energy use between XY%, depending on material hardness; this typically results in measurable savings on monthly power costs when replacing older technology mills.

Q3 What are the commercial terms regarding delivery?
A3 Delivery terms are FCA our manufacturing facility unless otherwise negotiated under an EPC contract; lead times vary based on model complexity but typically range within YZ weeks after final design approval.

Q4 How does implementation affect ongoing operational staffing?
A4 The design prioritizes operator safety and ease of service; routine tasks like screen inspection require fewer personnel manhours compared to mills requiring manual bolt removal procedures

Q5 Are spare parts readily available?
A5 We maintain strategic inventories of critical wear parts including rotors bearings screens etc.; availability levels depend upon your selected service package tier ensuring minimal disruption should replacement be necessary

Q6 Você pode fornecer garantias de desempenho?
A6 Yes we offer guaranteed performance metrics including throughput capacity product gradation curves maximum power draw etc.; these guarantees are formalized within our sales contract based upon agreed test protocols using representative feedstock samples