تصديق ٿيل سيمينٽ پلانٽ جي سامان جو ڊيلر
1. PAINPOINT driven اوپننگ
مسلسل انتظام ڪرڻ, سيمينٽ جي پيداوار ۾ خام مال ۽ ڪلينر جي تيز مقدار جي وهڪري هڪ مسلسل رڪاوٽ آهي. Inefficient or unreliable material transport directly impacts your plant’s throughput, توانائي جو واھپو, and maintenance overhead. Are you facing these specific challenges with your current system?
سار سنڀال لاءِ اضافي وقت: Frequent chain failures, ڦاٽڻ, or misalignment in conveying systems can halt an entire production line, گم ٿيل پيداوار ۾ هزارين في ڪلاڪ خرچ.
اعلي توانائي واپرائڻ: Inefficient drives and outdated conveying technology contribute significantly to your plant’s power bill, منافعي جي مارجن کي ختم ڪرڻ.
Material Degradation & ڦاٽڻ: Improper handling during transport leads to product loss through dust generation and spillage, creating cleanup costs and potential environmental compliance issues.
محدود لچڪدار & اسڪاليبلٽي: Inflexible systems struggle to adapt to changes in feedstock or required throughput, hindering process optimization and expansion plans.
Rising Operational & حفاظتي خطرا: 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. پيداوار جو جائزو: HeavyDuty Apron Feeders
هڪ Heavyduty apron فيڊر هڪ مضبوط آهي, continuousduty machine designed for controlled volumetric feeding of abrasive, ڳرو, and largesized materials—such as limestone, شيل, ڪلينر, 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.
آپريشنل ڪم فلو:
1. لوڊشيڊنگ: Material is directly dumped onto the feeder pans from a dump hopper or under a stockpile.
2. ٽرانسپورٽ: The interconnected pans are pulled by heavyduty chains driven by a gearboxconnected motor. The material rides on the solid pan surface.
3. خارج ٿيڻ: Material is carried horizontally or on an incline to a controlled discharge point, typically onto a conveyor belt or directly into a crusher.
ايپليڪيشن جو دائرو: ROM جي پرائمري فيڊنگ لاءِ مثالي (RunofMine) مواد, 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.
حدون: Not suitable for fine powders alone; higher initial capital cost compared to some belt feeders; requires more substantial foundational support due to weight.
3. بنيادي خاصيتون
Forged Alloy Chain System | ٽيڪنيڪل بنياد: Hightensile strength alloy steel with precision heat treatment | آپريشنل فائدا: Provides exceptional resistance to shock loading and abrasion from heavy materials like limestone boulders | ROI اثر: فيلڊ ڊيٽا تائين ڏيکاري ٿو 40% longer service life compared to standard chains, reducing replacement frequency and associated downtime costs.
Segmented Overlapping Pans | ٽيڪنيڪل بنياد: Cast manganese steel pans with boltedon liners | آپريشنل فائدا: Contains material completely, minimizing spillage and dust; worn liners can be replaced individually without removing entire pan sections | ROI اثر: Lowers material loss and reduces liner replacement labor time by an average of 35%.
متغير فريڪوئنسي ڊرائيو (وي ايف ڊي) ڪنٽرول | ٽيڪنيڪل بنياد: AC motor control allowing precise adjustment of motor speed and torque | آپريشنل فائدا: Enables exact feed rate control from 10% جي طرف 100% capacity to match downstream process demand; provides softstart capability | ROI اثر: Optimizes crusher or mill feed for maximum efficiency; reduces inrush current during startup, lowering energy costs.
مهربند & Lubricated Roller Bearings | ٽيڪنيڪل بنياد: Labyrinth seals with automatic grease purge systems at each head shaft bearing | آپريشنل فائدا: Excludes abrasive dust from critical bearing surfaces under high load conditions | ROI اثر: برداشت واري زندگي کي ختم ڪري ٿو 50%, preventing unplanned stoppages due to bearing seizure.
Modular Pan & فريم ڊيزائن | ٽيڪنيڪل بنياد: Bolttogether frame sections and standardized pan modules | آپريشنل فائدا: ٽرانسپورٽ کي آسان بڻائي ٿو, installation onsite within confined spaces like existing feed floors; facilitates future length extensions | ROI اثر: تنصيب جو وقت تقريباً گھٽائي ٿو 25% versus welded monolithic frames.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري ايپرن فيڊر | اسان جي HeavyDuty Apron فيڊر حل | فائدو (% سڌارو) |
| : | : | : | : |
| ناڪامين جي وچ ۾ وچولي وقت (ايم بي ايف) زنجير سسٽم| ~8,000 operating hours| >12,000 ڪم جا ڪلاڪ| +50% |
| Energy Efficiency at Rated Load| بيس لائين (100%)| آپٽمائزڊ ڊرائيو ٽرين & VFD ڪنٽرول| تائين 15% reduction in kW/ton |
| Pan Liner Replacement Time (per segment)| ~ 4 ڪلاڪ (full weld/bolt)| ~2.5 hours (modular bolton)| 37% |
| Maximum Handling Capacity (tph)| Varies by width/design| Engineered head shaft & drive for 20% overload capacity| +20% surge capability |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان 500 TPH کان مٿي 3,000 TPH standard models; custom engineering available.
بجلي جي گهرج: کان موٽرس ذريعي هلائي 75 kW کان 400 kW+, supplied with IP66 protection rating for harsh environments. Compatible with plant voltages up to 6.6kV.
مواد جي وضاحت: Pans: ASTM A128 Grade BHN Manganese Steel liners on structural steel bases. زنجير: جڙيل مصري اسٽيل, heattreated for hardness core with tough exterior.
جسماني طول و عرض: Standard widths from 1.5m to 3m; lengths customized from 4m to over 30m. Incline capability up to 25 درجا.
ماحولياتي آپريٽنگ رينج: ماحول جي درجه حرارت جي حد: 20°C کان +45°C. Capable of handling material temperatures up to 120°C continuously (special designs available for hotter clinker).
6. درخواست جا منظر
Cement Plant Primary Crushing Feed | چيلنج: A plant experienced chronic downtime due to belt feeder ripping under impact from large (>1م) limestone boulders from the quarry ROM pad. Spillage was severe.| حل: Installation of a widewidth heavyduty apron feeder between the dump hopper and jaw crusher.| نتيجا: Eliminated feederrelated stoppages entirely for over two years since installation; spillage reduced by an estimated 95%; crusher feed rate stabilized for optimal operation.
ڪلينر کولر ڊسچارج هينڊلنگ | چيلنج: گرم ڪلينر (لڳ ڀڳ. 80°C) was causing excessive wear on standard conveyor belts at the cooler outlet, leading to quarterly belt replacements.| حل: Implementation of an inclined apron feeder designed for elevated temperatures as the first stage transporter.| نتيجا: Conveyor belt life extended threefold; total system availability increased due to predictable wear patterns on replaceable apron pan liners.
7. تجارتي خيالات
قيمت جا درجا: Configured based on width/length/capacity specifications:
ٽائر I (2500 ٽي پي ايڇ): Customengineered superheavy duty design.
اختياري خاصيتون: 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.
سروس پيڪيجز دستياب:
ڪميشن جي حمايت
Annual Inspection Program
Critical Spare Parts Kits
آن سائيٽ ٽريننگ
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.FAQ
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
