Export Quarry Ballast Crushing Equipment Quotation
Targeted Quarry Ballast Crushing Equipment: Разработано для максимальной производительности и минимального времени простоя
1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT
Производство последовательных, Железнодорожный балласт специального качества является основным фактором прибыльности карьеров., yet the crushing process presents persistent operational challenges. Вы столкнулись:
Чрезмерное начисление штрафов: До 20% of processed material can fall below the required gradation, turning potential revenue into lowvalue byproduct.
Незапланированный простой: Frequent liner changes and wear part failures in abrasive granite, базальт, or gneiss applications halt your primary production line for costly maintenance windows.
Непоследовательная форма продукта: Poor cubicity and excessive flaky material in your ballast product can lead to rejection by rail authorities, requiring recrushing and stockpiling issues.
Высокие эксплуатационные расходы: Rising energy consumption per ton and the cumulative expense of rapid wear part consumption directly erode your margin on every cubic meter of ballast shipped.
Rigid Process Flow: Inflexible crusher settings struggle to adapt to natural variations in feed stone size or hardness, causing bottlenecks and quality control headaches.
Центральный вопрос для руководителей предприятий заключается в следующем.: how can you increase the percentage of highvalue, inspec ballast while systematically reducing cost per ton and unplanned stoppages?
2. ОБЗОР ПРОДУКТА
Our dedicated quarry ballast crushing equipment is a highperformance cone crusher series specifically configured for secondary and tertiary reduction of hard, abrasive aggregates into railway ballast. The operational workflow is designed for integration into existing plant layouts:
1. Primary Feed Reception: Accepts screened oversize material (+40мм) from your primary jaw or gyratory crusher.
2. Прецизионное снижение: Utilizes a combination of high inertia and an optimized crushing chamber geometry to fracture stone along natural lines.
3. Формирование продукта: Interparticle comminution within a packedbed chamber promotes the production of cubic, wellshaped particles critical for ballast interlock.
4. Контроль градации: Гидравлическая регулировка положения закрытой стороны (CSS) allows realtime tuning to meet exacting BS, АРЕМА, or local rail specifications (например, 5025мм).
5. Прямой разряд: Crushed product is conveyed to final screening decks, minimizing chip rehandling and degradation.
Область применения & Ограничения:
Идеально подходит для: Secondary/tertiary crushing of granite, ловушка для камня, базальт, and other high PSI (250+ МПа) aggregates for railway ballast and construction armor stone.
Ограничения: Not designed as a primary crusher for runofquarry material exceeding a top size of 250mm. Not suitable for processing recycled concrete or asphalt (РАП/РКА) without significant configuration changes.
3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ
Настройка CSS Hydroset | Техническая основа: Hydraulic piston supporting main shaft | Операционная выгода: Operators can adjust crusher gap settings in under 60 seconds from a remote location for precise gradation control. | Воздействие на рентабельность инвестиций: Устраняет остановки производства для ручной регулировки прокладок, увеличение эксплуатационной готовности установки примерно на 23%.
Многослойная дробильная камера | Техническая основа: Optimized feed opening, длина параллельной зоны, and throw profile | Операционная выгода: Creates a rockonrock crushing action that reduces liner wear by up to 30% on abrasive stone while enhancing particle shape cubicity. | Воздействие на рентабельность инвестиций: Lowers costperton for manganese steel consumables and improves saleable product yield.
Автоматическая компенсация износа | Техническая основа: PLCintegrated system monitoring hydraulic pressure and piston position | Операционная выгода: Automatically maintains the preset closedside setting as liners wear, ensuring consistent product gradation throughout the liner lifecycle without manual intervention. | Воздействие на рентабельность инвестиций: Reduces product quality variation by over 70%, virtually eliminating offspec batches.
High Inertia AntiFriction Bearings | Техническая основа: Largediameter heavyduty roller bearings supporting eccentric assembly | Операционная выгода: Sustains high crushing forces with lower friction losses than bushingtype designs, handling peak loads from uncrushable material via tramp release. | Воздействие на рентабельность инвестиций: Полевые данные показывают 1520% снижение удельного энергопотребления (кВтч/тонна) по сравнению со старыми конструкциями дробилок.
Система удержания вкладыша | Техническая основа: Mechanically locked backing compound and boltin design | Операционная выгода: Secures mantle and concave liners firmly, preventing movement that causes premature fatigue failure and reducing liner changeout time by up to 40%. | Воздействие на рентабельность инвестиций: Shortens planned maintenance downtime directly impacting annual throughput capacity.
4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА
| Метрика производительности | Отраслевой стандарт (Средняя конусная дробилка) | Наше решение для дробления балласта в карьерах | Преимущество (% Улучшение) |
| : | : | : | : |
| Saleable Ballast Yield (% корма) | 6575% | 7885%| +10 к +15% |
| Лайнер Жизнь (Operating Hours Granite) | 800 1,200 часы| 1,400 1,800 часы| +40% |
| Энергопотребление (kWh per ton output)| Based on historical plant data| Configurable based on model selection| До 20% |
| Последовательность градаций (Std. Deviation in CSS)| High variation over liner life| Maintained within ±2mm via automation| +70% Последовательность |
| Среднее время между отказами (среднее время безотказной работы)| ~1500 часов| Отраслевые испытания показывают >2,200 часы| +30% Надежность |
5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ
Модельный ряд Вместимость: 150 – 800 тонн в час (ТПХ) of finished ballast product (50мм+25мм), depending on chamber selection and feed material.
Требования к питанию: Электромоторный привод от 150 кВт до 400 кВт. All models include softstart capability for reduced electrical network stress.
Характеристики материала: Основная рама из высококачественной литой стали; Austenitic manganese steel wear liners standard; Optional chromewhite iron liners available for specific highly abrasive feeds.
Физические размеры (Типичная модель): Приблизительно. Длина: 4м х ширина: 3м х высота: 3м (без учета загрузочного бункера). Weight ranges from ~18 to ~45 tonnes.
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 20°C до +45°C с соответствующими смазочными материалами.. Dust sealing is rated IP67 standard.
6. СЦЕНАРИИ ПРИМЕНЕНИЯ
Карьер Хард-Рок, снабжающий национальный железнодорожный проект | Испытание: A granite quarry’s existing secondary crusher produced over 22% fines when making Type A ballast, creating a significant waste stream during a highvolume infrastructure project.| Решение: Implementation of our HPCseries quarry ballast crushing equipment with a coarseliner chamber profile.| Результаты: Образование штрафов сократилось до уровня ниже 14%, increasing saleable yield by over 8%. The automated wear compensation maintained gradation compliance across weekly quality audits with zero nonconformance reports.
Regional Aggregate Producer Expanding Market Reach | Испытание: Need to produce both premium railway ballast and construction aggregate from the same plant without sacrificing flexibility or incurring excessive changeover downtime.| Решение: Installation of our multichamber capable cone crusher with two interchangeable liner sets.| Результаты: Changeover between rail spec aggregate and road base spec is achieved in one scheduled 8hour shift versus 24 hours previously required for major reconfiguration. This enabled the producer to service both markets competitively.
7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ
Our quarry ballast crushing equipment is offered in three primary tiers:
Стандартная конфигурация: For consistent feed materials. Включает дробилку стержня, приводной двигатель, базовая система смазки, and manual controls.
Конфигурация высокой доступности: Adds automated wear compensation PLC system advanced dust seals heavyduty filtration package remote monitoring ports
Turnkey Modular Skid Package: Crusher premounted on a structural steel skid complete with integrated feeders conveyors walkways safety systems
Дополнительные функции включают в себя:
Metal detection automatic tramp release systems
Lubrication oil condition sensors
Расширенная интеграция программного обеспечения для прогнозного обслуживания
Service packages range from annual inspection plans comprehensive longterm performance contracts including guaranteed parts availability financing options include equipment leasing capital loans through partner institutions tailored payperton agreements
8.Часто задаваемые вопросы
Q What primary crusher feed size is compatible with your quarry ballast crushing equipment?
A For optimal performance we recommend a maximum feed size not exceeding 250mm ideally prescreened at 40mm This ensures efficient operation prevents chokefeeding
Q How does this equipment impact our overall plant throughput?
A By increasing saleable yield reducing unplanned downtime field data typically shows net plant throughput increases between 5 15 depending on existing circuit limitations
Q Доступны ли изнашиваемые детали??
A We maintain regional inventory hubs stock all critical wearing parts including mantles concaves bushings Standard delivery lead times are under 72 hours supported by guaranteed supply agreements
Q What are typical installation requirements?
A The unit requires prepared concrete foundations adequate craneage lifting capacity electrical connection per model specifications Our engineering team provides full foundation drawings load data
Q Can we finance this equipment under an operating expense OpEx model?
A Yes we offer several flexible arrangements including rental leasetoown contracts based on monthly throughput volumes allowing you preserve capital expenditure CapEx budgets