1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Управление непрерывным, Большой поток сырья и клинкера является постоянным узким местом в производстве цемента.. Inefficient or unreliable material transport directly impacts your plant’s throughput, потребление энергии, and maintenance overhead. Are you facing these specific challenges with your current system?

Чрезмерное время простоя для технического обслуживания: Frequent chain failures, разлив, or misalignment in conveying systems can halt an entire production line, потери производительности обходятся тысячами в час.
Высокое энергопотребление: Inefficient drives and outdated conveying technology contribute significantly to your plant’s power bill, снижение прибыли.
Material Degradation & Разлив: Improper handling during transport leads to product loss through dust generation and spillage, creating cleanup costs and potential environmental compliance issues.
Ограниченная гибкость & Масштабируемость: Inflexible systems struggle to adapt to changes in feedstock or required throughput, hindering process optimization and expansion plans.
Rising Operational & Риски безопасности: Reliance on manual intervention for loading/unloading or dealing with constant jams increases exposure to safety incidents and repetitive strain injuries.

If these operational costs sound familiar, the specification of your bulk material handling equipment requires a critical review.

2. ОБЗОР ПРОДУКТА: HeavyDuty Apron Feeders

Пластинчатый питатель для тяжелых условий эксплуатации — это надежный, continuousduty machine designed for controlled volumetric feeding of abrasive, тяжелый, and largesized materials—such as limestone, сланец, клинкер, and slag—in primary crushing and raw mill feed applications. Its operation is based on a series of overlapping pans mounted on crawler chains that form a continuous moving bed.

Операционный рабочий процесс:
1. Загрузка: Material is directly dumped onto the feeder pans from a dump hopper or under a stockpile.
2. Транспорт: The interconnected pans are pulled by heavyduty chains driven by a gearboxconnected motor. The material rides on the solid pan surface.
3. Увольнять: Material is carried horizontally or on an incline to a controlled discharge point, typically onto a conveyor belt or directly into a crusher.

Область применения: Идеально подходит для первичной подачи ПЗУ (РуфМайн) материалы, handling hot clinker (up to specified temperature limits), and severeduty applications with high impact loads. It is the preferred solution where belt feeders would be cut or punctured.

Ограничения: Not suitable for fine powders alone; higher initial capital cost compared to some belt feeders; requires more substantial foundational support due to weight.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Forged Alloy Chain System | Техническая основа: Hightensile strength alloy steel with precision heat treatment | Операционная выгода: Provides exceptional resistance to shock loading and abrasion from heavy materials like limestone boulders | Воздействие на рентабельность инвестиций: Полевые данные отображаются до 40% longer service life compared to standard chains, reducing replacement frequency and associated downtime costs.

Segmented Overlapping Pans | Техническая основа: Cast manganese steel pans with boltedon liners | Операционная выгода: Contains material completely, minimizing spillage and dust; worn liners can be replaced individually without removing entire pan sections | Воздействие на рентабельность инвестиций: Lowers material loss and reduces liner replacement labor time by an average of 35%.

Частотно-регулируемый привод (ЧРП) Контроль | Техническая основа: Управление двигателем переменного тока, обеспечивающее точную регулировку скорости и крутящего момента двигателя. | Операционная выгода: Enables exact feed rate control from 10% к 100% capacity to match downstream process demand; provides softstart capability | Воздействие на рентабельность инвестиций: Optimizes crusher or mill feed for maximum efficiency; reduces inrush current during startup, lowering energy costs.

Запечатанный & Lubricated Roller Bearings | Техническая основа: Labyrinth seals with automatic grease purge systems at each head shaft bearing | Операционная выгода: Excludes abrasive dust from critical bearing surfaces under high load conditions | Воздействие на рентабельность инвестиций: Продлевает срок службы подшипников более чем 50%, preventing unplanned stoppages due to bearing seizure.

Modular Pan & Дизайн рамы | Техническая основа: Bolttogether frame sections and standardized pan modules | Операционная выгода: Упрощает транспортировку, installation onsite within confined spaces like existing feed floors; facilitates future length extensions | Воздействие на рентабельность инвестиций: Сокращает время установки примерно 25% versus welded monolithic frames.

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Пластинчатый питатель промышленного стандарта | Наше решение для пластинчатых питателей для тяжелых условий эксплуатации | Преимущество (% Улучшение) |
| : | : | : | : |
| Среднее время между отказами (среднее время безотказной работы) Цепная система| ~8000 часов работы| >12,000 часы работы| +50% |
| Energy Efficiency at Rated Load| Базовый уровень (100%)| Оптимизированная трансмиссия & Управление ЧРП| До 15% reduction in kW/ton |
| Pan Liner Replacement Time (per segment)| ~4 часа (полный сварной шов/болт)| ~2.5 hours (modular bolton)| 37% |
| Maximum Handling Capacity (т/ч)| Varies by width/design| Engineered head shaft & drive for 20% overload capacity| +20% surge capability |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Диапазон мощности: От 500 TPH превышает 3,000 TPH standard models; custom engineering available.
Требования к питанию: Приводится в движение двигателями от 75 кВт до 400 кВт+, supplied with IP66 protection rating for harsh environments. Compatible with plant voltages up to 6.6kV.
Характеристики материала: Сковороды: ASTM A128 Grade BHN Manganese Steel liners on structural steel bases. Цепи: Кованая легированная сталь, heattreated for hardness core with tough exterior.
Физические размеры: Стандартная ширина от 1,5м до 3м.; lengths customized from 4m to over 30m. Incline capability up to 25 степени.
Экологический рабочий диапазон: Диапазон температур окружающей среды: 20°С до +45°С. Capable of handling material temperatures up to 120°C continuously (special designs available for hotter clinker).

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Cement Plant Primary Crushing Feed | Испытание: A plant experienced chronic downtime due to belt feeder ripping under impact from large (>1м) limestone boulders from the quarry ROM pad. Spillage was severe.| Решение: Installation of a widewidth heavyduty apron feeder between the dump hopper and jaw crusher.| Результаты: Eliminated feederrelated stoppages entirely for over two years since installation; spillage reduced by an estimated 95%; crusher feed rate stabilized for optimal operation.

Обращение с разгрузкой охладителя клинкера | Испытание: Горячий клинкер (приблизительно. 80°С) was causing excessive wear on standard conveyor belts at the cooler outlet, leading to quarterly belt replacements.| Решение: Implementation of an inclined apron feeder designed for elevated temperatures as the first stage transporter.| Результаты: Conveyor belt life extended threefold; total system availability increased due to predictable wear patterns on replaceable apron pan liners.

7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Ценовые уровни: Configured based on width/length/capacity specifications:
Уровень I (2500 ТПХ): Customengineered superheavy duty design.

Дополнительные функции: Integrated weighing systems (belt scale), automatic lubrication systems tailored for specific intervals/conditions wear monitoring sensors integrated into chain pins full guarding packages per local regulations.

Доступные пакеты услуг:

Поддержка при вводе в эксплуатацию
Annual Inspection Program
Critical Spare Parts Kits
Обучение на месте

Financing options include capital lease operating lease structures tailored project financing through our industrial finance partners terms typically range from months years depending upon agreement structure

8.Часто задаваемые вопросы

Q1.Is this equipment compatible with our existing PLCbased control system?
Yes all variable frequency drives come equipped standard communication protocols such as Modbus TCP/IP Profibus DP allowing integration into most modern plant distributed control systems

Q2.What is typical lead time delivery?
For standard capacity models within our Tier II range lead time averages weeks Custom engineered highcapacity units require detailed engineering plan accordingly

Q3.Does installation require extensive foundation work?
The modular frame design simplifies foundation requirements however due significant weight dynamic loads proper reinforced concrete foundations are essential Detailed civil drawings are provided part our technical package

Q4.How does this address operator safety concerns?
The fully enclosed pan design contains material reducing dust exposure risk The inclusion zerospeed switches ensures machinery cannot start unexpectedly during inspection All rotating parts are guarded per ISO standards

Q5.What warranty coverage provided?
We offer months comprehensive warranty covering defects materials workmanship Extended warranty options are available purchase covering major components such as chains sprockets gearboxes

Q6.Can you supply matching spare parts years down line?
Yes we maintain digital manufacturing records all major components ensuring that replacement parts will match original specifications exactly even decades after initial purchase

Q7.Are performance guarantees offered?
Yes we provide guaranteed minimum throughput capacity based on specified material characteristics along with guaranteed power consumption envelope under defined operating conditions