برآمد ڪواري ballast ڪرشنگ سامان Fabricators
Targeted Solutions for Quarry Ballast Crushing: Overcoming Cost and Downtime Challenges
Are you managing inconsistent ballast gradation, leading to product rejection and wasted material? Struggling with frequent liner changes and unplanned downtime that disrupt your aggregate production schedule? Confronted with rising energy costs per ton of processed rock and excessive wear part expenditures that erode your profit margins? The efficiency of your primary crushing stage dictates the entire downstream process. How can you increase throughput of specification ballast while reducing operational complexity and total cost of ownership?
پيداوار جو جائزو: HeavyDuty Primary Jaw Crushers for Ballast Production
Our engineered primary jaw crusher series is specifically built for the continuous, highvolume crushing of hard, abrasive feed rock (مثال, گرينائيٽ, بيسالٽ) to produce railway ballast and construction aggregates. آپريشنل ڪم فلو قابل اعتماد لاء ٺهيل آهي: (1) Oversized feed material is loaded into the vibrating grizzly feeder, which removes fines to bypass the crusher. (2) The remaining rock is directed into the deep crushing chamber of the jaw crusher. (3) A single toggle, highinertia design applies massive compressive force to fracture the rock. (4) Crushed material discharges at a consistent, preset closed side setting (سي ايس ايس) to ensure firstpass gradation compliance. (5) The product conveyor transports sized aggregate for secondary screening.
This equipment is optimal for stationary or semimobile primary crushing plants. It is not designed as a portable unit or for processing recycled concrete with high rebar content without specific prescreening and tramp iron protection.
بنيادي خاصيتون: بالسٽ منافعي لاءِ انجنيئر
جارحتي ڪرشنگ جاميٽري | ٽيڪنيڪل بنياد: Steep nip angle and deep symmetrical chamber | آپريشنل فائدا: وڌ ۾ وڌ سائيز جي گھٽتائي في چڪر, increasing throughput of hard rock and reducing slabby output. | ROI اثر: في ڪلاڪ وڌيڪ ٽين (ٽي پي ايڇ) directly lowers costperton for capitalintensive operations.
هائيڊولڪ ٽوگل & ترتيب ڏيڻ وارو نظام | ٽيڪنيڪل بنياد: Replaceable hydraulic cylinder for tensioning and clearing blockages. | آپريشنل فائدا: Enables rapid, inchamber clearing of tramp material without manual intervention; لوڊ جي تحت محفوظ CSS ترتيب ڏيڻ جي اجازت ڏئي ٿي. | ROI اثر: Minimizes downtime from stalls; بچائڻ جو اندازو لڳايو 1015 hours of labor annually per crusher.
HeavyDuty رولر بيئرنگ ڊيزائن | ٽيڪنيڪل بنياد: Spherical selfaligning roller bearings with larger bore diameters. | آپريشنل فائدا: Supports higher load capacities and peak crushing forces, extending bearing service life under severe duty cycles. | ROI اثر: تباهي واري بيئرنگ ناڪامي جي خطري کي گھٽائي ٿو; فيلڊ ڊيٽا ڏيکاري ٿو a 3040% ناڪامي جي وچ ۾ وچولي وقت ۾ بهتري (ايم بي ايف) معياري ڊيزائن جي مٿان.
BoltOn Wear Liners | ٽيڪنيڪل بنياد: Modular cheek and side plates secured with captive bolts. | آپريشنل فائدا: لائنر جي متبادل کي آسان بڻائي ٿو; تائين تبديل ٿيندڙ وقت گھٽائي ٿو 50% ويلڊ ٿيل ڊيزائن جي مقابلي ۾. | آپريشنل فائدا: Improves safety by minimizing time personnel spend in the crusher cavity.
انٽيگريڊ موٽر بيس & ڊرائيو گارڊز | ٽيڪنيڪل بنياد: کولہو لاءِ متحد بيس پليٽ, موٽر, ۽ مڪمل مشيني نگهباني سان ڍڪيل. | آپريشنل فائدا: Eliminates alignment issues during installation; provides compliant safety protection as standard. | ROI اثر: تائين انسٽاليشن وقت گھٽائي ٿو 20% and ensures immediate site safety compliance.
مقابلي جا فائدا: مقدار جي قابل ڪارڪردگي ميٽرڪس
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | اسان جي جبڑے کولہو حل | فائدو (% سڌارو) |
| : | : | : | : |
| دستيابي (مقرر ٿيل آپريٽنگ وقت) | 9294% | 96%+ | پيداواري ڪلاڪن ۾ ~ 4 سيڪڙو اضافو |
| لائنر زندگي (ابراھيندڙ گرينائيٽ) | 180,000 220,000 ٽين | 250,000 300,000 ٽين| تائين 36% سڌارو |
| طاقت جي ڪارڪردگي (kWh/ٽن) پٿر جي قسم جي لحاظ کان مختلف آهي| بيس لائين = 100%| انڊسٽري ٽيسٽ ڏيکاري ٿو a 58% reduction.| Direct energy cost savings |
| ذريعي جي گنجائش ساڳئي CSS تي & ايڇ پي| بيس لائين = 100%| تائين 15% higher TPH due to optimized kinematics.| Higher yield from existing feed |
Based on controlled field trials with comparable feed material.
ٽيڪنيڪل وضاحتون
گنجائش جي حد: 300 1,800 MT/hr (ماڊل تي منحصر)
فيڊ کولڻ: Up to 60” x 80” for large boulder processing
بجلي جي گهرج: 150 450 kW برقي موٽر ڊرائيو
مواد جي وضاحت: اعلي طاقت جو ٺهيل اسٽيل فريم; Austenitic مينگنيز اسٽيل جوڙو مري ويو; AR steel cheek plates.
اهم جسماني طول و عرض: لڳ ڀڳ. ڊگھائي (feed to discharge): ماڊل جي لحاظ کان مختلف آهي; typical footprint is optimized for foundation requirements.
ماحولياتي آپريٽنگ رينج: مناسب لوبريڪيشن سسٽم سان گڏ 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل. Dusttight sealing standard.
ايپليڪيشن منظرنامو
Hard Rock Quarry, Railway Ballast Supply
چيلنج: A national rail ballast supplier needed consistent production of EN 13450 specification aggregate but faced excessive wear on pivot points and premature liner failure in their existing crushers, causing weekly maintenance stops.
حل: Implementation of a heavyduty jaw crusher featuring the hydraulic toggle system and bolton wear liners as the primary stage.
نتيجا: Liner changeout time reduced from 24 ڪلاڪ کان هيٺ 10 ڪلاڪ في واقعي. Crusher availability increased by over 300 هر سال ڪلاڪ, ensuring reliable supply against fixed rail network maintenance contracts.
Integrated Aggregate Plant Producing Multiple Products
چيلنج: A largescale plant producing ballast, روڊ جو بنياد, and concrete aggregates required greater flexibility in primary product sizing without sacrificing throughput or creating bottlenecks.
حل: Installation of a highcapacity jaw crusher with a hydraulic adjustment system allowing quick CSS changes.
نتيجا: Operators can adjust primary crush size in under minutes to optimize flow for different product blends, increasing overall plant flexibility by an estimated 22%. Firstpass yield to ballast specification improved by over eight percentage points.
تجارتي خيالات
Equipment pricing is structured across three capability tiers:
1. معياري ڊيوٽي: For lowerabrasion applications (<400 ايم پي اي compressive طاقت).
2. ڳري ڊيوٽي (Recommended for Ballast): مڪمل خصوصيت سيٽ جيئن مٿي بيان ڪيو ويو آهي.
3. سپر ڊيوٽي: For extremeabrasion feeds or maximum yearly tonnage (>3 ملين ٽن).
اختياري خاصيتن ۾ شامل آهن خودڪار لوبريڪيشن سسٽم, حصو مانيٽرنگ سينسر پائڻ, ۽ ڪسٽم خارج ڪرڻ وارو ڪنويئر انٽرفيس.
Service packages range from basic commissioning support through comprehensive annual inspection contracts with guaranteed parts availability.
Financing options include capital purchase leasing plans tailored to project cash flow cycles or longterm rentaltoown agreements managed through our financial partners.
اڪثر پڇيا ويا سوال
Q1: Is this equipment compatible with our existing secondary cone crushers and screening plant?
A1: ها. Our engineering team will review your current plant layout and product flow requirements to ensure seamless integration regarding feed size acceptance rates conveyor capacities
Q2 What impact will installing this have on our overall plant energy consumption?
A2 Due its higher throughput efficiency power draw per ton processed typically decreases However total plant energy use depends on secondary stage optimization We provide projected kWh ton metrics based on your specific feed analysis
Q3 What are typical lead times from order placement commissioning?
A3 For standard heavy duty models lead time ranges from weeks months depending configuration Customizations may extend this A detailed project schedule provided upon quotation
Q4 What warranty coverage offered?
A4 We provide month comprehensive warranty covering workmanship materials extended coverage available critical components like main frame shaft through optional service agreements
Q5 Do you provide training our operations maintenance staff?
A5 Yes Onsite training during commissioning mandatory covering safe operation routine maintenance troubleshooting procedures Additional training modules available
Q6 Can you assist obtaining spare parts inventory analysis optimize our stockholding?
A6 Our service team conducts audit your current usage patterns recommend critical spares kit minimize risk production stoppages offer consignment stock arrangements key accounts
Q7 Are turnkey installation project management services available?
A7 We offer full EPC scope supply including civil design foundation drawings mechanical erection electrical connection supervised commissioning through qualified partner network
