1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Are you managing recurring bottlenecks and hidden costs in your size reduction process? Непостоянное распределение частиц по размерам, замена изнашиваемых деталей, and unplanned downtime for maintenance are not just operational nuisances—they directly erode your profitability and throughput. Рассмотрим эти общие проблемы:
Высокие эксплуатационные расходы: Частая замена молотков, экраны, and liners due to premature wear, compounded by labor costs for changeovers.
Непоследовательный вывод: Variable feed materials lead to an inconsistent final grind size, compromising downstream process efficiency and product quality.
Чрезмерное время простоя: Длинный, complex maintenance procedures for internal inspections and part replacements halt your entire production line.
Энергетическая неэффективность: Older or poorly designed hammer mills waste significant power on vibration, нагревать, and ineffective impact, rather than productive comminution.
Пыль & Шумовое загрязнение: Inadequate sealing and damping create environmental and safety hazards, leading to potential compliance issues and worker discomfort.

Is your current equipment delivering predictable performance and total cost of ownership? The solution lies in selecting a hammer mill engineered not just to crush material, but to optimize your entire operational workflow.

2. ОБЗОР ПРОДУКТА

Our industrial hammer mill is a heavyduty impact crusher designed for highvolume reduction of mediumhard to soft materials. It is a core component in aggregate production, предварительная обработка минералов, limestone grinding for agricultural lime or flue gas desulfurization (ФГД), и операции по переработке.

Операционный рабочий процесс:
1. Контролируемая подача: Материал вводится через регулируемую систему подачи. (например, ленточный конвейер, вибрационный питатель) в камеру измельчения.
2. Высокоскоростной удар: Ротор в сборе, оснащенный свободно качающимися или жесткими молотками, вращается с высокой скоростью., repeatedly striking the incoming material against breaker plates.
3. Классификация размеров: Crushed particles pass through a surrounding screen or grate; only material meeting the specified size exits the chamber.
4. Увольнять & Транспортировка: Sized material is discharged via gravity or pneumatic system for further processing or stockpiling.

Область применения & Ограничения:
Идеально подходит для: Известняк, гипс, уголь, агрегаты, recycled asphalt pavement (РЭП), бетон для сноса, bark, and other friable materials.
Ограничения: Not recommended for very abrasive materials (например, кварцевый песок) без особых вариантов сплава, высокопластичные металлы, or materials with high moisture content that may cause clogging without proper conditioning.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Реверсивная роторная система | Техническая основа: Symmetrical rotor design allows endforend rotation of hammers | Операционная выгода: Удваивает срок службы передних кромок молота до замены.; reduces inventory by standardizing parts | Воздействие на рентабельность инвестиций: Cuts wear part costs by up to 40% over the lifecycle of the unit

Динамическая балансировка | Техническая основа: Computeraided rotor balancing postassembly at operating RPM | Операционная выгода: Minimizes vibration transmission to bearings and foundation; обеспечивает более плавную работу на высоких скоростях | Воздействие на рентабельность инвестиций: Продлевает срок службы подшипников в среднем на 30% and reduces structural fatigue

QuickAccess Clamshell Design | Техническая основа: Hinged housing sections secured by hydraulic rams or largebore bolts | Операционная выгода: Full interior access for inspection, изменения экрана, or hammer rotation in under 30 минуты | Воздействие на рентабельность инвестиций: Reduces standard maintenance downtime by approximately 70%, увеличение годовой пропускной способности

Сегментированные износостойкие вкладыши | Техническая основа: Bolton liner plates manufactured from AR400 or chromium carbide alloys | Операционная выгода: Individual sections can be replaced as needed without dismantling the entire mill housing | Воздействие на рентабельность инвестиций: Lowers liner replacement cost by targeting only worn areas; simplifies logistics

Air Assist & Интеграция пылеподавления | Техническая основа: Sealed housing with ports for negative pressure systems or controlled air flow | Операционная выгода: Manages internal airflow to reduce heat buildup and directs fine particulates to collection systems | Воздействие на рентабельность инвестиций: Improves operational safety (reduces explosion risk), обеспечивает соблюдение экологических требований

Сферические роликовые подшипники для тяжелых условий эксплуатации | Техническая основа: Oversized bearing housings with labyrinth seals and grease purge systems | Операционная выгода: Handles high radial loads from unbalanced feed conditions; excludes contaminants | Воздействие на рентабельность инвестиций: Provides reliable service in highshock environments with extended lubrication intervals

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Стандартный эталон отрасли | Наше решение для молотковой мельницы | Документированное преимущество |
| : | : | : | : |
| Тоннаж на кВтч (Limestone 6mm) | 8 10 Тонн/кВтч | 11 13 Тонн/кВтч| +2030% Энергоэффективность |
| Время смены экрана (Полный комплект) | 4 6 Часы| 120k MTon| +50% Повышенная надежность |
| Уровень шума при 1 Метр (дБА) >100 дБА|<95 dBA with standard housing|<5 Снижение дБА |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Диапазон мощности: Модельзависит от 25 TPH превышает 300 TPH on limestone (25mm feed to 3mm product).
Требования к питанию: От 75 кВт (100 HP) до 750 кВт (1000 HP), configured for VSD control where applicable.
Диаметр ротора & Ширина: From Ø800mm x 800mm up to Ø2000mm x 2500mm.
Строительные материалы: Mainframe – Fabricated steel plate (мин. 25мм). Hammers/Screens – Highcarbon steel/AR400/Chrome iron alloys optional. Liners – AR400 standard; ceramic composite optional.
Физические размеры & Масса: Значительно различается в зависимости от модели; largest units require planned foundation work (~1540 metric tons).
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 20°С до +45°С.. Dust ingress protection rating of IP54 standard.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Завод по производству сельскохозяйственной извести

Challenge A producer needed consistent fine grind (2мм) of limestone at 150 TPH but faced weekly downtime for screen changes and monthly hammer replacements due to abrasive silica content in the feedstock.

Solution Implementation of a heavyduty hammer mill featuring a reversible rotor with tungsten carbidetipped hammers and quickaccess clamshell doors.

Results Screen change time reduced from one full shift (8 часы) to under two hours. Hammer life extended from ~10k tonnes to over 28k tonnes. Annual availability increased by an estimated 12%, achieving target throughput with one less scheduled maintenance day per month.

Строительство & Завод по переработке сноса

Challenge Processing mixed C&D waste into clean aggregate was hampered by frequent jamming from noncrushables (пряди арматуры) causing severe rotor damage and belt slippage.

Solution Installation included a nonclogging steppedgrate screen design paired with shearbolt protected hammers on a lowinertia rotor that could be stopped quickly.

Results Incidents of catastrophic jamming dropped by over 90%. The shearbolt system protected the main shaft and bearings during overload events. Overall plant uptime improved significantly while reducing repair part expenditures by an estimated 35% ежегодно.

7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Наши молотковые мельницы предлагаются на трех основных уровнях.:

1. Standard Duty Series For consistent feed materials requiring reliable performance at lower capital outlay.
2 Heavy Duty Series The core offering described here includes all major features like reversible rotors quickaccess design ideal for most mining aggregate applications
3 Extreme Duty Series Engineered for maximum abrasion resistance featuring specialized alloys automated lubrication systems advanced monitoring sensors

Optional Features Upgrades include programmable logic controller PLCbased monitoring packages automatic greasing systems explosion suppression systems custom discharge configurations

Service Packages Available options range from basic commissioning supervision through comprehensive multiyear planned maintenance agreements including guaranteed parts availability priority technical support

Financing Options We work with international export credit agencies project finance partners equipment leasing companies Flexible payment structures can be tailored including milestone payments upon delivery commissioning

8 Часто задаваемые вопросы

Q What level of preparation is required for my feedstock before using this hammer mill
A For optimal performance feed should be prescreened to remove fines already at specification size Maximum feed size should not exceed 80% of the screen aperture opening Material moisture content should generally remain below 15% depending on clay content

Q How does this hammer mill integrate with my existing conveying dust collection systems
A Our engineering team provides detailed interface drawings specifying inlet outlet flange dimensions load points electrical requirements Standard units are designed for integration into both gravityfed pneumatic conveying circuits

Q What is the typical lead time from order placement commissioning
A Lead times vary based on model specification For standard heavyduty models expect approximately 1620 weeks exworks including manufacturing testing documentation preparation Expedited production may be available subject inquiry

Q Can you provide wear part consumption estimates specific my material analysis
A Yes Based on your provided sample we conduct laboratory testing generate a detailed wear forecast outlining expected service life hammers screens liners under defined operating conditions This forms basis our guaranteed performance agreements

В Какую подготовку прошел наш персонал по техническому обслуживанию?
A Comprehensive training included covers safe operation routine maintenance troubleshooting procedures conducted both our facility during onsite commissioning We provide detailed operation manuals parts lists instructional videos