1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão minando a lucratividade da sua pedreira? Para gerentes de fábrica e empreiteiros de engenharia, producing consistent, highquality railway ballast presents distinct challenges. Material de alimentação inconsistente leva à geração excessiva de finos, falhando na distribuição rigorosa do tamanho das partículas (PSD) specifications and resulting in product rejection. Frequent liner wear in crushing chambers increases maintenance intervals, causing costly production halts. High energy consumption per ton of final product directly impacts your bottom line. Além disso, the need for multiple crushing stages to achieve the cubical shape required for optimal track bed stability often complicates plant layout and increases capital expenditure.

How do you increase yield of specification ballast while controlling wear costs and energy use? The efficiency of your primary crushing stage is fundamental to solving these problems.

2. VISÃO GERAL DO PRODUTO

Esta linha de produtos abrange serviços pesados, stationary primary jaw crushers engineered specifically for highvolume quarry ballast production. The operational workflow is designed for maximum reliability: (1) ROM (RunofMine) feed is delivered to the vibrating grizzly feeder, que remove finos naturais e ignora material subdimensionado; (2) Oversize material is directed into the deep crushing chamber of the jaw crusher for initial compression breaking; (3) The crushed material is discharged onto a main conveyor at a consistent, optimized size for secondary processing. This equipment is designed for hard rock applications (granito, basalto, armadilha de rocha) com alta abrasividade. It is not suited as a standalone solution for soft or highly friable rock without secondary shaping stages.

3. RECURSOS PRINCIPAIS

Geometria de esmagamento agressiva | Base Técnica: Steep nip angle and long stroke | Benefício Operacional: Generates higher throughput and effective size reduction in a single pass, reducing load on downstream cone crushers. | Impacto do ROI: Increases total plant capacity by 1015%, maximizando a utilização de ativos.

Construção de estrutura para serviços pesados | Base Técnica: Fabricated steel plate with reinforced ribbing and stressrelieved welding. | Benefício Operacional: Fornece durabilidade excepcional contra cargas de choque de materiais não trituráveis, minimizando a fadiga da estrutura e o risco de falha catastrófica. | Impacto do ROI: Prolonga a vida útil estrutural além 20 anos sob operação normal, protegendo o investimento de capital.

Sistema de revestimento modular | Base Técnica: Interchangeable cheek plate and jaw die segments secured by wedgelocking mechanisms. | Benefício Operacional: Reduces replacement downtime from days to hours. Allows strategic rotation of wear parts to utilize full material volume. | Impacto do ROI: Cuts liner changeout labor costs by up to 40% e aumenta a disponibilidade do britador.

Ajuste Hidráulico & Limpeza | Base Técnica: Integrated hydraulic cylinders for setting adjustment and clearing tramp metal/uncrushables. | Benefício Operacional: Permite ajuste remoto de CSS (Configuração lateral fechada) for quick product gradation changes and safe, rapid clearing of blockages without manual intervention. | Impacto do ROI: Minimiza paradas não planejadas; dados de campo mostram um 90% reduction in downtime related to chamber blockages.

Acionamento direto & Projeto do volante | Base Técnica: Hightorque motor coupled directly to eccentric shaft with optimized flywheel mass. | Benefício Operacional: Ensures consistent power transmission under peak loading conditions, maintaining constant velocity for improved particle shaping. | Benefício Operacional: Improves energy efficiency by reducing transmission losses common in Vbelt drives.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Solução de britagem de lastro de pedreira | Vantagem (% melhoria) |
| : | : | : | : |
| Vida útil do forro (Rocha Abrasiva)| 450,000 550,000 toneladas| 600,000 750,000 toneladas| +25% média |
| Consumo de energia| 0.85 1.1 kWh/tonelada| 0.72 0.90 kWh/tonelada| Até 18% redução |
| Rendimento Cúbico do Produto| ~65% postprimary| ~75% postprimary| +10 pontos percentuais |
| Tempo médio entre manutenção (MTBM)| ~450 horas| ~600 hours| +33% |
| Consistência de rendimento| +/ 15% variance during shift|< +/ 8% variance during shift| Variance reduced by nearly half |

5.ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: 500 1,800 MTPH (depende do material de feed e CSS)
Abertura de alimentação: Até 60” x 80” (1,500mm x 2.000 mm)
Requisito de energia: 200 400 kW electric drive
Especificações de materiais: Fabricado em aço ASTM A36; Jaw dies available in AR400 or manganese steel (1822%); Eixo forjado em liga de aço de alta resistência.
Principais dimensões físicas: Faixa de peso aproximada de 85,000 kg para 165,000 kg.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C com sistemas de lubrificação apropriados.

6. CENÁRIOS DE APLICAÇÃO

Granite Quarry – Railway Ballast Supply Contract

Desafio: A national rail project required consistent Grade A ballast supply at over 800 Mtph but faced frequent jaw crusher liner failures every six weeks due to highly abrasive granite.
Solução: Implementation of a primary jaw crusher featuring the modular liner system in manganese steel.
Resultados: Liner life extended to nine weeks per set while maintaining target throughput quantifiable outcomes included a direct reduction in wear part costs of $135k annually and a projected increase in annual production hours due to fewer changeouts.

Basalt Aggregate Producer – Plant Modernization

Desafio: An existing plant’s primary crusher produced excessive flaky material requiring additional processing stages poor particle shape reduced final ballast yield.
Solução: Replacement with a new primary jaw crusher engineered with aggressive geometry and optimal stroke.
Resultados: Postprimary cubical product yield increased from an average of production data confirmed an overall plant yield improvement allowing the contractor to fulfill two concurrent supply contracts without expanding secondary crushing capacity.

7. CONSIDERAÇÕES COMERCIAIS

Pricing tiers are structured based on crusher size feed opening capacity:
Tier I Standard Duty Configuration includes crusher motor drives basic guarding installation drawings
Tier II BallastOptimized Package adds hydraulic adjustment overflow chute specialized jaw die profile extended warranty
Tier III Turnkey Skid Module includes feeder scalping screen integral walkways ladders preassembled electricals

Optional features include automated lubrication systems wear monitoring probes dust suppression ring guards

Service packages are available as Bronze Silver Gold levels covering parts labor scheduled inspections Financing options include capital lease operating lease or projectbased financing terms typically ranging from months

8. Perguntas frequentes

What upstream equipment is needed?
A vibrating grizzly feeder is strongly recommended ahead of this crusher scalp out fines protect the chamber from unnecessary wear ensure even feed distribution across the jaw length

Can this equipment process recycled concrete or asphalt?
While capable it is not optimal design focuses on hard virgin rock using it for recycling may accelerate wear due to contaminants lower ROI compared dedicated recycling impactors

What are typical installation requirements?
Requires substantial reinforced concrete foundation detailed foundation drawings provided lead time from order commissioning averages months depending model site conditions

How does pricing compare total cost ownership TCO?
Initial investment may be higher than standard models however industry testing demonstrates lower TCO over year period due reduced energy consumption extended wear part life higher availability

Que treinamento proporcionou aos operadores a equipe de manutenção?
Comprehensive onsite training covers safe operation routine maintenance troubleshooting procedures detailed manuals video libraries accessible