Custom Quarry Ballast Crushing Equipment Fabricator
ھدف ٿيل ڪواري بيلسٽ کرشنگ حل: انجڻ جي ذريعي, تفصيل, and CostPerTon
1. PAINPOINT driven اوپننگ: غير موثر بالسٽ جي پيداوار جي اعلي قيمت
مسلسل پيداوار, specificationgrade ريلوي ballast quarries لاء هڪ بنيادي منافعي ڊرائيور آهي, yet the process is fraught with operational bottlenecks. Inefficient crushing directly impacts your bottom line through:
وڌ ۾ وڌ فائنس پيدا ڪرڻ: تائين 1520% material loss as unsellable fines, eroding potential revenue from every ton of feed.
ڪعبي & گريجوئيشن ناڪاميون: Outofspec product leads to batch rejection, ٻيهر ڪرڻ جي قيمت, and compromised relationships with rail contractors.
اڻ شيڊول بند وقت: بار بار لائنر تبديليون, component wear in abrasive granite/basalt applications, and unexpected breakdowns halt entire aggregate lines.
اعلي آپريشنل خرچ: Energyintensive processes and manual grading adjustments consume profit margins.
Are your current crushing circuits delivering optimal yield on hard, abrasive stone? Is your ballast product consistently meeting AREMA or local rail specifications without costly reprocessing? The solution lies in selecting a primary crusher engineered explicitly for the rigors of highvolume ballast production.
2. پيداوار جو جائزو: Primary Jaw Crusher for HighYield Ballast Production
This heavyduty primary jaw crusher is designed as the first stage in a dedicated ballast crushing circuit. It transforms blasted quarry run (typically 600800mm) into a manageable, ٿلهو مجموعو (لڳ ڀڳ. 150200ايم ايم) optimized for secondary cone crushing.
آپريشنل ڪم فلو:
1. Quarry run dump feed enters the largecapacity vibrating grizzly feeder (وي جي ايف ايف وي جي ايف), scalping out sub100mm natural fines.
2. Oversize material is directed into the deep crushing chamber of the jaw crusher.
3. A highstroke, aggressive nip angle fractures even the most slabby granite or trap rock.
4. Crushed material discharges onto a main conveyor at a consistent minus200mm size.
5. This product feeds directly into a secondary cone crusher set for final ballast gradation.
ايپليڪيشن جو دائرو: سخت پٿر لاء مثالي (گرينائيٽ, بيسالٽ, گنيس) quarries with annual production targets exceeding 500,000 tons of ballast. حدون: Not suitable for soft or highly weathered rock; requires prescreening via grizzly to maximize efficiency and protect the chamber from fines.
3. بنيادي خاصيتون: Engineering for BallastSpecific Performance
ڊيپ ڪرشنگ چيمبر & جارحتي نپ زاويه | ٽيڪنيڪل بنياد: Kinematic geometry of swing jaw | آپريشنل فائدا: Effective firstpass reduction of slabby rock minimizes bridging and produces a uniform feed for secondary crushing | ROI اثر: Reduces load on secondary circuit by up to 18%, lowering overall system energy consumption.
HeavyDuty باڪس فريم تعمير | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي) بهتر دٻاء جي ورڇ | آپريشنل فائدا: Eliminates frame fatigue and maintains bearing alignment under continuous highload operation with abrasive feed | ROI اثر: ڍانچي جي خدمت جي زندگي کي وڌايو 25 سال, سرمائيداري سيڙپڪاري جي حفاظت.
هائيڊولڪ ٽوگل ايڊجسٽمينٽ & صاف ڪرڻ وارو نظام | ٽيڪنيڪل بنياد: ڊبليڪٽنگ هائيڊولڪ سلنرز ميخانياتي ٽوگل پليٽ کي تبديل ڪن ٿا | آپريشنل فائدا: Allows remote adjustment of CSS for wear compensation and rapid clearing of stall events without manual intervention | ROI اثر: Reduces downtime for adjustments by an average of 85% دستي شيم سسٽم جي مقابلي ۾.
AR400 Manganese Jaw Dies with Optimal Tooth Profile | ٽيڪنيڪل بنياد: Material science and profile modeling for compressive fracture | آپريشنل فائدا: Maximizes throughput and promotes interparticle crushing for improved cubicity while extending wear life in abrasive applications | ROI اثر: فيلڊ ڊيٽا ڏيکاري ٿو a 3040% معياري مينگنيز مٿان لائنر جي زندگي ۾ بهتري, reducing costperton for wear parts.
انٽيگريڊ موٽر بيس & بيلٽ ڊرائيونگ جي حفاظت | ٽيڪنيڪل بنياد: Unified fabrication and safetybydesign principles | آپريشنل فائدا: تنصيب کي آسان بڻائي ٿو, ensures proper Vbelt tensioning, and provides complete operator safety guarding as standard | ROI اثر: Cuts installation time by two days and eliminates cost addons for mandatory safety components.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | Industry Standard Primary Jaw Crusher | Our BallastOptimized Jaw Crusher Solution | فائدو (% سڌارو) |
| : | : | : | : |
| Tonnage Yield of Specification Ballast (per kWh)| 100120 ٽين/MWh | 135150 ٽين/MWh | +25% جي طرف +30% |
| گرينائيٽ تي زندگي گذاريو (جيو مري)| ~ 180,000 ٽين | ~250,000 tons | +38% |
| سي ايس ايس ايڊجسٽمينٽ لاءِ سراسري وقت| 46 ڪلاڪ (دستور) | <1 ڪلاڪ (هائيڊولڪ) | 85% |
| Material Reduction Ratio (Blasted Run to Feed)| ~5:1 average ratio| مسلسل 6:1 جي طرف 7:1 تناسب| +20% جي طرف +40% |
5. ٽيڪنيڪل وضاحتون
ماڊل نامزدگي: BJC140
فيڊ کولڻ: 1400mm x 1100mm
Recommended Max Feed Size: 800mm lump
بند طرف سيٽنگ (سي ايس ايس) حد: 150mm 250mm
گنجائش جي حد (for ballast feed): 450 750 MTPH
ڊرائيو پاور جي گهرج: 200 kW برقي موٽر
ڪل وزن (صرف کولہو): ~ 62,000 ڪلوگرام
اهم مواد جي وضاحت: مکيه فريم ٺهيل اسٽيل پليٽ; Jaw dies premium AR400 manganese steel; Eccentric shaft جعل سازي مصر اسٽيل.
ماحولياتي آپريٽنگ رينج: Full operation from 20°C to +45°C ambient temperature.
6. درخواست جا منظر
[National Rail Infrastructure Project] چيلنج: A granite quarry supplying a major rail upgrade needed to guarantee consistent AREMA 4A gradation at volumes exceeding 2 million tons annually. Their existing primary crusher produced excessive fines (<9ايم ايم) and caused bottlenecks.
[حل]: Implementation of the BJC140 jaw crusher with a custom tooth profile matched to their specific granite geology.
[نتيجا]: Fines generation at the primary stage reduced from an estimated 18% هيٺ 11%. This directly increased saleable ballast yield by over 140,000 tons annually at project volume.
[Private Freight Rail Maintenance Contractor] چيلنج: A midsize quarry serving regional freight lines faced high downtime costs from tramp metal events and slow wear compensation adjustments on their aging primary crusher.
[حل]: Replacement with the BJC140 unit featuring the hydraulic toggle system.
[نتيجا]: Clearing uncrushables now takes under 10 منٽ بمقابله ڪيترائي ڪلاڪ اڳ. Quarterly CSS adjustments take 45 minutes instead of a halfshift, contributing to measured plant availability increase of 6%.
7. تجارتي خيالات
Our quarry ballast crushing equipment is offered under three primary tiers:
1. بنيادي سامان پيڪيج: Includes crusher assembly with standard jaw dies/manganese liners motor base/vbelts/sheaves.
2 Operational Efficiency Package: Base plus hydraulic toggle system automatic lubrication system extended warranty on bearings/shafts.
3 مڪمل پلانٽ انٽيگريشن پيڪيج: Includes customdesigned feeder/surge hopper integration controls interface/PLC compatibility installation supervision commissioning support
Financing options include capital lease operating lease projectbased financing terms typically structured over 3 7 years Service packages range from basic parts supply comprehensive scheduled maintenance programs including liner changeout inspections
Pricing reflects engineering grade fabrication component quality Direct consultation required final quotation based sitespecific configuration requirements
FAQ
What type secondary crusher works best this primary jaw?
For final ballasting gradation robust cone crushers set tight chamber typically recommended The uniform coarse aggregate produced this jaw optimizes feed secondary cone maximizing overall circuit cubicity minimizing flakiness
How does this handle very wet or sticky feed material?
While designed hard rock effective grizzly prescreening critical Wet sticky materials can exacerbate packing Standard recommendation includes heavyduty scalping separate natural fines before entry crushing chamber
What typical delivery lead time after order confirmation?
For standard BJC model lead time averages 16 weeks from deposit receipt Custom configurations may require additional engineering time Firm schedule provided upon project initiation
ڪارڪردگي جي ضمانت ڏني وئي آهي?
Yes performance guarantees based agreedupon site feed material characteristics Guarantees cover minimum throughput maximum power consumption specific product gradation band postsecondary crushing
ڇا جاري ٽيڪنيڪل سپورٽ موجود آهي?
Support includes detailed maintenance manuals remote diagnostics assistance parts inventory planning Onsite technician training included all packages optional annual service contracts available
