1. ABERTURA ACIONADA POR PAINPOINT

Are you managing a quarry ballast operation where inconsistent product gradation, geração excessiva de multas, and unplanned maintenance are eroding your margins? The primary challenges in producing highspecification railway ballast and construction aggregate are clear:
Gradation Inconsistency: Failure to consistently meet the strict particle size distribution (PSD) for railway ballast (por exemplo, AREMA, EM 13450) leads to product rejection, reesmagamento, and lost revenue.
Alto desgaste & Custos de tempo de inatividade: A natureza abrasiva do granito, basalto, and limestone rapidly degrades crusher liners and impact elements, causing frequent stoppages for component replacement and escalating your costpertonne.
Geração excessiva de multas: Improper crushing action creates an overabundance of 10mm material, which is waste in ballast production. This reduces your yield of premium, inspecionar produto.
Intensidade Energética: Inefficient crushing chambers and drive systems result in high power consumption per tonne of final product, impactando diretamente as despesas operacionais.
Plant Inflexibility: Fixedconfiguration crushers cannot adapt to varying feed material hardness or changing product specification demands without significant downtime for reconfiguration.

How do you increase the yield of premium quarry ballast while controlling wear costs and ensuring plant uptime? The answer lies in selecting purposeengineered quarry ballast crushing equipment.

2. VISÃO GERAL DO PRODUTO

This datasheet details our range of stationary and mobile primary jaw crushers and secondary cone crushers engineered specifically for highvolume quarry ballast production. These machines are designed to transform blasted rock into precisely graded, agregado cúbico.

Fluxo de Trabalho Operacional:
1. Redução Primária: Blasted feed (normalmente 750 mm) is introduced into a heavyduty jaw crusher. The deep crushing chamber and aggressive nip angle facilitate initial size reduction to a manageable 250mm product.
2. Secundário & Britagem Terciária: The primary crushed material is then fed into a cone crusher operating in a closed circuit with a sizing screen. This stage is critical for achieving the final cubical shape and exact gradation.
3. Dimensionamento & Recirculação: Oversize material from the screening deck is recirculated back to the cone crusher (operação em circuito fechado), while inspec quarry ballast is conveyed to stockpile.

Escopo de aplicação & Limitações:
Escopo: Ideal for medium to hard abrasive rock (Granito, Basalto, Quartzito). Suitable for both largescale stationary quarries and mobile contract crushing setups requiring relocation.
Limitações: Not designed for very soft or nonabrasive rock (por exemplo, chalk), where alternative crusher types may be more appropriate. O tamanho máximo de alimentação é determinado pelo modelo específico do britador primário selecionado.

3. RECURSOS PRINCIPAIS

Ajuste CSS do Hydroset | Base Técnica: Hydraulic piston adjusts the closedside setting (CSS) sob carga | Benefício Operacional: Allows operators to finetune product gradation in minutes without stopping the crusher, responding to realtime feed changes | Impacto do ROI: Eliminates production downtime for mechanical shim adjustments, increasing annual throughput by up to 7%

Liner Wear Compensation | Base Técnica: Automated system maintains CSS via hydraulic positioning as liners wear | Benefício Operacional: Delivers consistent product gradation over the full liner life without manual intervention | Impacto do ROI: Maintains premium product yield and reduces risk of offspec production by an average of 15%

MultiAction Crushing Chamber | Base Técnica: Optimized chamber geometry combines attrition, compressão, and interparticle crushing | Benefício Operacional: Promotes grainongrain breakage for superior particle shape with lower fines generation | Impacto do ROI: Increases saleable quarry ballast yield by 812% em comparação com câmaras padrão

Rolamento Pesado & Projeto de mainframe | Base Técnica: Forged alloy steel mainframe with oversized spherical roller bearings | Benefício Operacional: Sustains high shock loads from uncrushable material and ensures longterm structural integrity | Impacto do ROI: Extends major component service life beyond 20,000 horas, reducing total cost of ownership

Sistema de automação baseado em PLC | Base Técnica: Programmable Logic Controller with loadandlevel sensors for chokefed operation | Benefício Operacional: Mantém o nível ideal da cavidade automaticamente, maximizing throughput and protecting the crusher from damage | Impacto do ROI: Optimizes power draw efficiency by up to 10% and prevents costly overload events

Design fácil de usar | Base Técnica: Hydraulic tools for backing compound removal and topserviceable liner change design | Benefício Operacional: Reduces liner changeout time by over 50% compared to traditional bolton designs | Impacto do ROI: Reduz os custos de mão de obra por evento de manutenção e aumenta a disponibilidade da planta

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nossa solução de britagem de lastro de pedreira vantagem documentada |
| : | : | : |
| Rendimento do produto (+22mm 63mm) | ~6570% of feed mass typically within spec range based on industry averages >75% consistently achieved through optimized chamber design >75% consistently achieved through optimized chamber design |
| Vida útil do forro (Cone Secundário) ~500700 operating hours in abrasive granite >850 operating hours demonstrated in field trials >850 operating hours demonstrated in field trials |
| Energy Consumption ~0.8 1.1 kWh/tonne for secondary crushing ~0.65 0.9 kWh/tonne measured at multiple sites ~0.65 0.9 kWh/tonne measured at multiple sites |
| Gradation Consistency Standard deviation of ±8% on key sieve sizes Standard deviation tightened to ±4% via automation Standard deviation tightened to ±4% via automation |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: De 200 toneladas por hora (mobile configurations) acabar 1,200 tph (stationary primary/secondary plants).
Requisitos de energia: Unidades de mandíbulas primárias de 110400 kW; Unidades cônicas secundárias de 132315 kW. All drives compatible with VSDs for soft start capability.
Especificações de materiais: Designed for unconfined compressive strength (UCS) até 350 MPa. Crusher wear parts manufactured from Mn18Cr2 or equivalent highgrade manganese steel.
Dimensões Físicas (Exemplo de planta móvel): Comprimento: ~19m; Largura: ~3m; Altura: ~4m; Peso Operacional: ~48 tonnes.
Faixa operacional ambiental: Standard units rated for 20°C to +40°C ambient temperature. Dust suppression system connections standard on all models.

6. CENÁRIOS DE APLICAÇÃO

Railway Ballast Production Plant Challenge A national rail infrastructure contractor faced recurring penalties due to flaky particle content exceeding network standards from their existing cone crushers Solution Implementation of a tertiary cone crusher with a multiaction chamber specifically tuned for cubicity Results Particle elongation index (EI) reduced from 28% to below 15%, ensuring full compliance AREMA 4A spec Firstyear yield increased by approximately €180k due reduced waste fines

Granite Quarry Expansion Challenge A large granite quarry needed higher throughput without expanding their primary circuit footprint or increasing energy costs Solution Replacement of two older secondary crushers with a single highcapacity cone model featuring advanced automation Results Throughput increased by 22% while specific energy consumption fell by18%. Payback period on equipment was achieved within14 months through increased sales volume

Contract Crushing Operator Challenge A mobile crushing contractor required rapid setup teardown between sites while maintaining precise output gradations across varying geology Solution Deployment trackmounted jaw cone plant featuring hydraulic setting adjustment quick release conveyor systems Results Site mobilization time reduced by40%. Operators can recalibrate CSS hydraulically between sites ensuring spec compliance across different projects without downtime

7 CONSIDERAÇÕES COMERCIAIS

Our quarry ballast crushing equipment is offered across several tiers:
Configuração padrão: A costeffective package including core machine basic automation dust suppression
Pacote de alta disponibilidade: Includes upgraded wear monitoring telemetry extended warranty on major components
Turnkey Plant Design Engineering services site layout optimization integration with existing conveyors screens

Optional features include advanced rock level sensors automatic lubrication systems remote monitoring portals Service packages range from scheduled maintenance plans comprehensive life cycle contracts Financing options include capital purchase finance leases operational leases structured align payments project cash flow

8 Perguntas frequentes

What if my feed material hardness varies significantly throughout the quarry face?
The hydroset system allows quick CSS adjustment compensate variations Automation maintains choke feed ensuring consistent performance shape across different strata

How does this equipment integrate with my existing screening washing circuits?
Crushers are designed standard discharge heights conveyor widths Interface points clearly defined Our engineering team can provide integration drawings ensure compatibility

What typical operational training required for my team?
We provide comprehensive onsite training covering operation basic troubleshooting liner changes Most crews proficient within three five working days

Are wear parts readily available what expected lead times?
We maintain regional inventory critical wear parts Average lead time consumables like mantles concaves is under72 hours supported service network

What financing structures available beyond outright purchase?
We offer several models including3660 month finance leases which may offer tax benefits well as rental purchase agreements tailored seasonal cash flows