Bulk Stone Crusher Machine Catalog
Product Catalog: HighCapacity Bulk Stone Crusher Machine
1. درد پوائنٽ هلائيندڙ اوپننگ
Managing a highvolume crushing circuit for bulk stone presents persistent operational challenges that directly impact your bottom line. Are you facing excessive downtime from frequent jaw or cone liner changes, costing your plant upwards of $15,000 في ڪلاڪ گم ٿيل پيداوار ۾? Is your current throughput bottlenecked at 200 ٽين في ڪلاڪ (ٽي پي ايڇ) when your quarry feed demands 400+ ٽي پي ايڇ? Do you struggle with inconsistent product gradation, leading to rejected aggregates and rehandling costs? Are maintenance crews spending 40% of their shift on unplanned repairs instead of preventive tasks? These inefficiencies—wasted energy, high wear costs, and unreliable output—erode margins. The right bulk stone crusher machine must deliver consistent reduction ratios with minimal mechanical intervention.
2. پيداوار جو جائزو
هي bulk stone crusher machine هڪ سخت فرض آهي, electricallydriven horizontal shaft impactor (ايڇ ايس آءِ) or primary jaw crusher, مسلسل لاء ٺهيل, hightonnage reduction of limestone, گرينائيٽ, ۽ بيسالٽ. The operational workflow is streamlined for integration into existing fixed or mobile plants:
- کاڌ خوراڪ: ڪارخانو مواد (تائين 1,200 ايم ايم) is fed via a vibrating grizzly feeder, which scalps fines to reduce wear.
- پرائمري ڪرشنگ: The crusher rotor (or eccentric jaw) applies high compressive and impact forces, reducing stone to a 150200 mm پيداوار.
- ثانوي گھٽتائي: Material passes through adjustable breaker plates or a closedside setting (سي ايس ايس) for precise sizing.
- خارج ٿيڻ & اسڪريننگ: Crushed material exits onto a main conveyor, with an optional prescreen for closedcircuit operation.
- ايپليڪيشن جو دائرو: Ideal for primary and secondary crushing in aggregate quarries, کان کني جا عمل, ۽ وڏي پيماني تي تعميراتي منصوبا. Limitations include reduced efficiency with highly abrasive, highsilica materials (مثال, ڪوارٽزائٽ) بغير خاص لباس واري لائنر.
- ماڊل: BSC4500 (Primary HSI)
- ظرفيت جي درجه بندي: 400600 ٽي پي ايڇ (کاڌ خوراڪ جي سائيز ۽ مواد جي کثافت تي منحصر آهي)
- فيڊ کولڻ: 1,200 ايم ايم x 1,500 ايم ايم
- روٽر قطر: 1,300 ايم ايم
- بجلي جي گهرج: 315 ڪلواٽ (400 ايڇ پي) برقي موٽر, 480V/60Hz (يا 380V/50Hz), 3مرحلو
- مواد جي وضاحت: هاء ڪروم بلو بار (27% Cr), AR400 frame liners, 4340 alloy steel rotor shaft
- جسماني طول و عرض: 4.5 م (ايل) x 3.2 م (ڊبليو) x 3.8 م (ايڇ)
- وزن: 38,000 ڪلو (بغير موٽر)
- ماحولياتي آپريٽنگ رينج: 20°C کان 50°C; designed for outdoor operation with IP55 motor enclosure
- سامان جي قيمت جا درجا:
- اختياري خاصيتون: Wireless remote control ($4,500), خودڪار lubrication نظام ($6,200), spare rotor assembly ($35,000).
- سروس پيڪيجز:
- فنانسنگ جا اختيار: Available through thirdparty lenders with terms of 3660 مهينا, 0% down for qualified buyers, or leasetoown options starting at $8,500/month.
3. بنيادي خاصيتون
HeavyDuty روٽر اسيمبلي | ٽيڪنيڪل بنياد: Forged alloy steel rotor with a high moment of inertia | آپريشنل فائدا: Maintains kinetic energy during peak loads, reducing stall risk | ROI اثر: 1215% increase in throughput consistency, lowering perton energy cost by $0.08
هائيڊولڪ ايڊجسٽمينٽ سسٽم | ٽيڪنيڪل بنياد: PLCcontrolled hydraulic cylinders for breaker plate positioning | آپريشنل فائدا: آپريٽرز هيٺ ڏنل شين جي سائيز کي تبديل ڪري سگھن ٿا 5 مينوئل شيمنگ کان سواءِ منٽ | ROI اثر: جي ذريعي تبديلي جي گھٽتائي گھٽائي ٿي 70%, شامل ڪرڻ 2+ في شفٽ جي پيداوار جا ڪلاڪ
WearResistant لائنر جي جوڙجڪ | ٽيڪنيڪل بنياد: هاء ڪروم (27% Cr) or ceramic composite blow bars and liners | آپريشنل فائدا: جي ذريعي سروس جي زندگي کي وڌايو 40% abrasive گرينائيٽ اپليڪيشن ۾ | ROI اثر: پاران سالياني لباس حصن جي خرچن کي گھٽائي ٿو $18,000 في کولہو
مربوط اوورلوڊ تحفظ | ٽيڪنيڪل بنياد: Shear pin or hydraulic relief system on the main shaft | آپريشنل فائدا: ناقابل برداشت ٽراپ ڌاتو کان تباهي واري نقصان کي روڪي ٿو | ROI اثر: ختم ڪري ٿو $50,000+ repair events, هڪ سان 99.2% uptime guarantee in field tests
متغير اسپيڊ ڊرائيو (وي ايس ڊي) اختيار | ٽيڪنيڪل بنياد: VFDcontrolled motor for rotor speed adjustment | آپريشنل فائدا: Optimizes reduction ratio for different feed materials without mechanical changes | ROI اثر: ذريعي توانائي جي ڪارڪردگي کي بهتر بڻائي ٿو 810%, بچت $6,500 annually in electricity costs
مٽي کي دٻائڻ وارو نظام | ٽيڪنيڪل بنياد: Internal water spray nozzles with misting control | آپريشنل فائدا: تنفس جي قابل سليڪا مٽي کي گھٽائي ٿو 85% کولہو جي خارج ٿيڻ تي | ROI اثر: Lowers compliance costs and operator health risks, avoiding potential OSHA fines
ماڊل فريم ڊيزائن | ٽيڪنيڪل بنياد: ڦاٽل, skidmounted construction with lifting points | آپريشنل فائدا: Enables rapid relocation or integration into existing plants within 48 ڪلاڪ | ROI اثر: Cuts installation labor costs by 30% ويلڊڊ ڍانچي جي مقابلي ۾
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (Singletoggle Jaw) | وڏي پٿر Crusher مشين (ايڇ ايس آءِ) | فائدو (% سڌارو) |
| : | : | : | : |
| ذريعي (ٽي پي ايڇ) | 250350 ٽي پي ايڇ | 400600 ٽي پي ايڇ | +4070% |
| گھٽتائي جي شرح | 4:1 جي طرف 6:1 | 8:1 جي طرف 12:1 | +50100% |
| ڪعبي پيداوار جي شڪل | 6070% ڪعبي | 8592% ڪعبي | +2530% |
| بجلي جو استعمال (kWh/ٽن) | 0.8 1.2 kWh/ٽن | 0.5 0.7 kWh/ٽن | 3040% |
| لائنر زندگي (گرينائيٽ) | 1,200 ڪلاڪ | 1,800 ڪلاڪ | +50% |
| تبديليءَ جو وقت (لينر) | 812 ڪلاڪ | 46 ڪلاڪ | 50% |
5. ٽيڪنيڪل وضاحتون
6. ايپليڪيشن منظرنامو
چونا پٿر جي کوٽائي جي توسيع | چيلنج: Existing jaw crusher limited plant output to 250 ٽي پي ايڇ, causing truck queuing and overtime costs. | حل: Installed a BSC4500 bulk stone crusher machine as a primary, feeding a secondary cone circuit. | نتيجا: تائين وڌايو ويو 480 ٽي پي ايڇ, reducing haul truck cycle time by 20 منٽ في لوڊ. Annual production rose by 180,000 ٽين, with a payback period of 14 مهينا.
Granite Road Base Production | چيلنج: High wear costs ($0.45/ٽين) and poor cubicity (65%) from a traditional cone crusher, leading to rejected material for base course. | حل: Deployed the HSI model with ceramic blow bars and a VSD for speed optimization. | نتيجا: Wear costs dropped to $0.28/ton. Cubical product increased to 90%, eliminating recrushing. ڪلائنٽ بچايو $22,000 annually in liner costs.
Mobile Plant Relocation | چيلنج: Contractor needed a crusher that could be moved between three sites within a year, with minimal foundation work. | حل: Utilized the modular frame design of the bulk stone crusher machine, mounted on a skid with hydraulic legs. | نتيجا: Relocation completed in 36 ڪلاڪ في سائيٽ. Setup time reduced from 5 ڏينهن تائين 1.5 ڏينهن, بچت $14,000 in crane and labor costs per move.
7. تجارتي خيالات
معياري پيڪيج (Base HSI): $380,000 $450,000 (موٽر شامل آهي, ويبلٽ ڊرائيو, بنيادي ڪنٽرول پينل)
ترقي يافته پيڪيج (with VSD & هائيڊولڪ ايڊجسٽمينٽ): $480,000 $550,000 (includes VFD, پي ايل سي, ريموٽ نگراني)
پريميئم پيڪيج (with Dust Suppression & Ceramic Liners): $560,000 $650,000 (includes full wear kit, اسپري سسٽم, ۽ 2 سال وارنٽي)
بنيادي (سالياني): $12,000/سال (includes one site inspection, ريموٽ سپورٽ)
جامع (3سال): $30,000/سال (ٽه ماهي معائنو شامل آهن, ترجيحي حصا, ۽ 24/7 tech support)
8. FAQ
ق: Can this bulk stone crusher machine handle wet or sticky material?
اي: ها, the open rotor design and adjustable breaker plates reduce clogging. سان گڏ مواد لاء >15% نمي, we recommend the optional heated discharge chute and belt scraper kit.
ق: ترسيل لاءِ عام ليڊ ٽائيم ڇا آهي?
اي: معياري ماڊل اندر ٻيڙيون 810 آرڊر کان هفتي. ڪسٽم ترتيبون (مثال, specific motor voltage) گهربل 1214 هفتا.
ق: How does this machine compare to a gyratory crusher for primary crushing?
اي: For throughputs under 600 ٽي پي ايڇ, this HSI offers lower capital cost (3040% گهٽ) and better product shape. Gyratory crushers are preferred for >1,000 TPH applications with extremely hard rock.
ق: وارنٽي ڪوريج ڇا آهي?
اي: 12 ڪم ڪرڻ کان مهينا يا 18 موڪلن کان مهينا, جيڪو پهرين اچي. The premium package extends this to 24 مهينا. Wear parts are excluded.
ق: Can I retrofit this into an existing plant without major civil works?
اي: ها, the modular skid design requires only a level concrete pad (minimum 6m x 4m x 0.5m thick). Our engineering team provides a site layout drawing within 2 آرڊر جا هفتا.
ق: متوقع سالياني سار سنڀال جي قيمت ڇا آهي?
اي: لاءِ 400 TPH آپريشن, بجيٽ $25,000$35,000 annually for wear parts and $8,000 for labor. هي آ 20% lower than comparable jaw/cone combinations.
ق: ڇا توهان آپريٽر ٽريننگ فراهم ڪندا آهيو?
اي: ها, a 2day onsite training session is included with all packages. This covers startup, بند ڪريو, CSS ترتيب ڏيڻ, ۽ حفاظت پروٽوڪول.
