Quarry Ballast Crushing Equipment Private Label Manufacturer Samples
Целевые решения для дробления балласта в карьерах: Разработан для обеспечения пропускной способности, Spec, and CostPerTon
1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT
Производство последовательных, Железнодорожный балласт требуемого качества является важной, но требовательной операцией.. Непостоянный исходный материал, абразивная порода, and stringent gradation requirements create persistent challenges that directly impact your bottom line. Вы столкнулись:
Чрезмерный износ & Незапланированный простой: Are premature liner failures and component wear in your secondary/tertiary stage causing costly, unscheduled shutdowns and ballooning parts inventories?
OffSpec Product & Потеря урожайности: Is a significant portion of your output failing to meet the strict particle shape (кубичность) and size distribution (градация) required for rail ballast, forcing material to be recrushed or downgraded?
Высокие эксплуатационные расходы: Are your energy consumption per ton and maintenance labor hours exceeding projections, eroding profit margins on every cubic meter of ballast shipped?
Негибкое производство: Does your current circuit struggle to maintain optimal performance with varying feed sizes or rock hardness, requiring constant manual adjustment and risking spec deviation?
Если эти операционные препятствия кажутся вам знакомыми, the selection of your tertiary or quaternary crushing stage is not just an equipment purchase—it’s a strategic decision determining plant profitability.
2. ОБЗОР ПРОДУКТА: HIGHPERFORMANCE CONE CRUSHER FOR BALLAST PRODUCTION
This solution centers on a heavyduty cone crusher specifically configured for the final shaping and sizing stages in quarry ballast production. Engineered to transform secondary crushed aggregate into precise, highintegrity railway ballast.
Операционный рабочий процесс:
1. Контролируемая подача: Correctly sized feed from secondary crushing (typically 80mm) is introduced via a regulated feeding system.
2. Межчастичное измельчение: The rock is compressed and crushed multiple times between the mantle and concave liners within a packed crushing chamber.
3. Точный контроль размера: The crusher’s hydraulic adjustment system allows realtime control of the closedside setting (CSS), determining the final product top size.
4. Consistent Discharge: Измельченный материал выходит из камеры, achieving the required cubicity for optimal interlock and drainage in rail applications.
Область применения & Ограничения:
Идеально подходит для: Tertiary or quaternary reduction of granite, базальт, ловушка для камня, и другие тяжелые, abrasive aggregates to produce 2850mm or 31.563mm standard railway ballast.
Ограничения: Не предназначен для первичной дробилки карьерного материала.. Maximum feed size is dependent on model selection but typically does not exceed 80120mm for optimal ballast production.
3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ
Усовершенствованная конструкция камеры | Техническая основа: Ламинированный принцип дробления с оптимизированной кинематикой | Операционная выгода: Promotes interparticle crushing to produce a consistent output with superior particle shape (высокая кубичность) and fewer elongated/flaky particles. | Воздействие на рентабельность инвестиций: Increases saleable ballast yield by an average of 815%, reducing waste and recirculating load.
Гидравлическая регулировка настроек (HSA) Система | Техническая основа: Remote hydraulic control of the crusher’s closedside setting (CSS) под нагрузкой. | Операционная выгода: Allows operators to make precise CSS adjustments in under one minute without stopping the crusher to compensate for wear or change product spec. | Воздействие на рентабельность инвестиций: Сокращает время простоя для регулировки до 90% по сравнению с ручными системами прокладок, прямое повышение эксплуатационной готовности оборудования.
AntiSpin & Head Speed Control | Техническая основа: Patented mechanism that limits the spin of the mantle to prevent uncontrolled rotation at noload or lightload conditions. | Операционная выгода: Reduces liner wear evenly and decreases power spikes during startup or empty chamber conditions. | Воздействие на рентабельность инвестиций: Продлевает срок службы гильзы до 30%, lowering consumable costs per ton and stabilizing energy consumption.
Автоматизированная система управления (СКУД) Интеграция | Техническая основа: PLCbased system monitoring critical parameters like power draw, давление, уровень полости, и CSS. | Операционная выгода: Provides realtime data and can automatically regulate feed rate or perform corrective actions to protect the crusher from overloads and maintain optimal performance. | Операционная выгода: Protects major components from damage due to tramp metal or uncrushables through rapid hydraulic release and reset.
Подшипник для тяжелых условий эксплуатации & Строительство мейнфреймов | Техническая основа: Largediameter spherical roller bearings supported within a fabricated steel mainframe of highstrength plate. | Операционная выгода: Provides high radial load capacity for continuous heavyduty operation with hard abrasive rock common in ballast quarries.| Воздействие на рентабельность инвестиций: Ensures longterm structural integrity and reliability, minimizing risk of catastrophic failure that leads to extended outages.
4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА
| Метрика производительности | Базовый уровень отраслевого стандарта | Our Ballast Cone Crusher Solution | Документированное преимущество |
| : | : | : | : |
| Срок службы вкладыша (Абразивный камень) | Reference = 100% (например, 450тыс. тонн) | Utilizes proprietary manganese steel chemistry & конструкция камеры | +25% к +35% increased tonnage per liner set |
| Энергоэффективность (кВтч/тонна) | Reference = 100% | Оптимизированная кинематика & antispin technology reduce noload losses| До 10% снижение удельного энергопотребления |
| Кубичность продукта (% ratio) | Typical cone output (~7580% cubic)| Advanced chamber geometry promotes interparticle breakage| Achieves consistent >85% cubicity meeting stringent rail specs |
| Доступность (% Время работы) | Excludes planned maintenance stops| Hydraulic setting adjustment & robust design reduce unplanned stops| Полевые данные показывают >96% mechanical availability in ballast duty |
| Установка времени регулировки (Минуты)| Ручная система прокладок (~6090 min)| Hydraulic Setting Adjustment under load (<2 мин)| Downtime reduction exceeding 95% |
5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ
Модельный ряд Вместимость: 120 – 550 метрические тонны в час готового балласта (dependent on closedside setting and material characteristics).
Требования к питанию: Главный привод дробилки от 132 кВт до 315 кВт (200 – 500 HP). Hydraulic system requires additional auxiliary power.
Характеристики материала: Engineered for maximum feed size of ≤80mm (120mm optional). Constructed with highstrength steel mainframe; concaves/mantles in premiumgrade manganese steel (M2/M7).
Физические размеры / Масса: Зависит от модели; approximate footprint range of 3m x 2m up to 5m x 4m; weights from ~15 tonnes up to ~35 tonnes.
Экологический рабочий диапазон: Standard design operates in ambient temperatures from 20°C to +40°C (4от °F до +104 °F). Optional heating/cooling packages available for extreme climates.
6. СЦЕНАРИИ ПРИМЕНЕНИЯ
Гранитный карьер, снабжающий национальную железнодорожную сеть
Испытание: A major quarry's existing tertiary cone crushers produced excessive fines (<22мм) and elongated particles when producing Type A Ballast (31.563мм), ведущие к 20% yield loss as material was rejected or reprocessed.
Решение: Implementation of two specialized cone crushers configured with a "ballastoptimized" crushing chamber profile.
Результаты: Product cubicity improved from an average of 78% к +87%. Saleable ballast yield increased by 18%, effectively adding significant revenue from existing reserves without increasing blast volume.
Regional Aggregate Producer Adding Rail Ballast Line
Испытание: A contractor needed a compact tertiary circuit capable of switching between concrete aggregate (22мм) и железнодорожный балласт (50мм) production without lengthy changeover periods.
Решение: Installation of a single multipurpose cone crusher equipped with Hydraulic Setting Adjustment (HSA).
Результаты: Changeover between product settings is now achieved in under five minutes via the control panel versus a previous twohour manual process on older equipment, providing exceptional operational flexibility.
7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ
Our quarry ballast crushing equipment is offered through flexible commercial models designed for capital planning:
Ценовые уровни оборудования: Based on model capacity (+/200т/ч / +/400т/ч / +500т/ч+) with corresponding levels of standard automation.
Дополнительные функции / Пакеты:
Расширенный пакет автоматизации (full ACS with feed control integration)
Система контроля износа гильзы
Dust Sealing Package
360degree Maintenance Platform
HighAmbient or ColdClimate Kits
Услуга & Support Packages: Available as annual contracts covering scheduled inspections, приоритетная отправка запчастей (+24/48hr options), technical support access.
Варианты финансирования: We work with accredited partners able provide equipment leasing structures tailored typical mining/aggregate project cash flows
Часто задаваемые вопросы
1.Q What upstream equipment configuration works best feeding this cone crusher for ballast?
A For optimal results we recommend feeding it screened overflow from secondary stage typically jaw impactor This ensures consistent well distributed choke fed conditions maximize particleonparticle breakage
2.Q How does this solution handle occasional uncrushable material tramp metal?
A The integrated overload protection system utilizes hydraulic cylinders support mainshaft It allows temporary opening discharge pass uncrushable then automatically returns original setting without stopping process
3.Q What typical lead time expected major wear parts mantles concaves?
A We maintain strategic regional inventory critical consumables Standard manganese liners typically available exstock within region Customized profiles may require longer lead time based production schedule
4.Q Can existing plant PLC control system integrate new crushers automation?
A Yes Our control systems designed communicate via standard industrial protocols Modbus TCP/IP Profibus etc allowing central control room monitor adjust key parameters
5.Q What key factors determine correct model selection our operation?
A Primary factors are required finished product capacity tph desired CSS range type hardness abrasiveness feed material Detailed application review our engineering team recommended ensure fit
6.Q Предоставляются ли гарантии производительности??
A Yes We offer guaranteed capacity throughput based agreed test protocol specific material Guarantees also cover mechanical availability provided recommended maintenance schedules followed
7.В Какую подготовку прошел наш персонал по техническому обслуживанию??
A Comprehensive commissioning training included covers safe operation daily checks basic troubleshooting procedures Maintenance training focuses liner change procedures system diagnostics optional advanced sessions available