Export Quarry Ballast Crushing Equipment Quotation
ھدف ٿيل ڪواري بيلسٽ کرشنگ جو سامان: وڌ ۾ وڌ پيداوار ۽ گھٽ ۾ گھٽ گھٽ وقت لاءِ انجنيئر
1. PAINPOINT driven اوپننگ
مسلسل پيداوار, specificationgrade ريلوي ballast quarries لاء هڪ بنيادي منافعي ڊرائيور آهي, yet the crushing process presents persistent operational challenges. ڇا توهان کي منهن ڏيڻو آهي:
وڌ ۾ وڌ فائنس پيدا ڪرڻ: تائين 20% of processed material can fall below the required gradation, turning potential revenue into lowvalue byproduct.
غير منصوبا بند وقت: Frequent liner changes and wear part failures in abrasive granite, بيسالٽ, or gneiss applications halt your primary production line for costly maintenance windows.
غير مطابقت واري پيداوار جي شڪل: Poor cubicity and excessive flaky material in your ballast product can lead to rejection by rail authorities, requiring recrushing and stockpiling issues.
اعلي آپريشنل خرچ: Rising energy consumption per ton and the cumulative expense of rapid wear part consumption directly erode your margin on every cubic meter of ballast shipped.
Rigid Process Flow: Inflexible crusher settings struggle to adapt to natural variations in feed stone size or hardness, causing bottlenecks and quality control headaches.
پلانٽ مينيجرز لاءِ مرڪزي سوال هي آهي: how can you increase the percentage of highvalue, inspec ballast while systematically reducing cost per ton and unplanned stoppages?
2. پيداوار جو جائزو
Our dedicated quarry ballast crushing equipment is a highperformance cone crusher series specifically configured for secondary and tertiary reduction of hard, abrasive aggregates into railway ballast. The operational workflow is designed for integration into existing plant layouts:
1. Primary Feed Reception: Accepts screened oversize material (+40ايم ايم) from your primary jaw or gyratory crusher.
2. درستي جي گھٽتائي: Utilizes a combination of high inertia and an optimized crushing chamber geometry to fracture stone along natural lines.
3. پيداوار جي شڪل: Interparticle comminution within a packedbed chamber promotes the production of cubic, wellshaped particles critical for ballast interlock.
4. درجه بندي ڪنٽرول: بند ٿيل سيٽنگ جي هائيڊولڪ ترتيب (سي ايس ايس) allows realtime tuning to meet exacting BS, آريما, or local rail specifications (مثال, 5025ايم ايم).
5. سڌو سنئون ڇڏڻ: Crushed product is conveyed to final screening decks, minimizing chip rehandling and degradation.
ايپليڪيشن جو دائرو & حدون:
لاء مثالي: Secondary/tertiary crushing of granite, پٿر جو پٿر, بيسالٽ, and other high PSI (250+ ايم پي اي) aggregates for railway ballast and construction armor stone.
حدون: Not designed as a primary crusher for runofquarry material exceeding a top size of 250mm. Not suitable for processing recycled concrete or asphalt (RAP/RCA) without significant configuration changes.
3. بنيادي خاصيتون
هائيڊرو سيٽ سي ايس ايس ايڊجسٽمينٽ | ٽيڪنيڪل بنياد: Hydraulic piston supporting main shaft | آپريشنل فائدا: Operators can adjust crusher gap settings in under 60 seconds from a remote location for precise gradation control. | ROI اثر: دستي شيم ترتيبن لاءِ پيداوار جي اسٽاپ کي ختم ڪري ٿو, هڪ اندازي مطابق پلانٽ جي دستيابي کي وڌائڻ 23%.
MultiLayer کرشنگ چيمبر | ٽيڪنيڪل بنياد: Optimized feed opening, parallel zone length, and throw profile | آپريشنل فائدا: Creates a rockonrock crushing action that reduces liner wear by up to 30% on abrasive stone while enhancing particle shape cubicity. | ROI اثر: Lowers costperton for manganese steel consumables and improves saleable product yield.
خودڪار لباس معاوضو | ٽيڪنيڪل بنياد: PLCintegrated system monitoring hydraulic pressure and piston position | آپريشنل فائدا: Automatically maintains the preset closedside setting as liners wear, ensuring consistent product gradation throughout the liner lifecycle without manual intervention. | ROI اثر: Reduces product quality variation by over 70%, virtually eliminating offspec batches.
High Inertia AntiFriction Bearings | ٽيڪنيڪل بنياد: Largediameter heavyduty roller bearings supporting eccentric assembly | آپريشنل فائدا: Sustains high crushing forces with lower friction losses than bushingtype designs, handling peak loads from uncrushable material via tramp release. | ROI اثر: فيلڊ ڊيٽا ڏيکاري ٿو a 1520% مخصوص توانائي جي استعمال ۾ گهٽتائي (kWh/ٽن) پراڻي کولہو ڊيزائن جي مقابلي ۾.
لائنر برقرار رکڻ جو نظام | ٽيڪنيڪل بنياد: Mechanically locked backing compound and boltin design | آپريشنل فائدا: Secures mantle and concave liners firmly, preventing movement that causes premature fatigue failure and reducing liner changeout time by up to 40%. | ROI اثر: Shortens planned maintenance downtime directly impacting annual throughput capacity.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (سراسري مخروط کولہو) | اسان جي Quarry Ballast کرشنگ حل | فائدو (% سڌارو) |
| : | : | : | : |
| Saleable Ballast Yield (% کاڌ خوراڪ جو) | 6575% | 7885%| +10 جي طرف +15% |
| لائنر زندگي (Operating Hours Granite) | 800 1,200 ڪلاڪ| 1,400 1,800 ڪلاڪ| +40% |
| توانائي جو واھپو (kWh per ton output)| Based on historical plant data| Configurable based on model selection| تائين 20% |
| درجه بندي مطابقت (Std. Deviation in CSS)| High variation over liner life| Maintained within ±2mm via automation| +70% تسلسل |
| ناڪامي جي وچ ۾ وچولي وقت (ايم بي ايف)| ~ 1,500 ڪلاڪ| انڊسٽري ٽيسٽ ڏيکاري ٿو >2,200 ڪلاڪ| +30% اعتبار |
5. ٽيڪنيڪل وضاحتون
ماڊل رينج جي گنجائش: 150 - 800 ٽين في ڪلاڪ (ٽي پي ايڇ) of finished ballast product (50mm+25mm), depending on chamber selection and feed material.
بجلي جي گهرج: اليڪٽرڪ موٽر ڊرائيو کان 150 kW کان 400 ڪلواٽ. All models include softstart capability for reduced electrical network stress.
مواد جي وضاحت: هاء گريڊ کاسٽ اسٽيل مکيه فريم; Austenitic manganese steel wear liners standard; Optional chromewhite iron liners available for specific highly abrasive feeds.
جسماني طول و عرض (عام ماڊل): لڳ ڀڳ. ڊگھائي: 4m x ويڪر: 3م x اوچائي: 3م (فيڊ هاپر کان سواء). Weight ranges from ~18 to ~45 tonnes.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي گرمي پد لاء ٺهيل مناسب لوبريڪنٽ سان. Dust sealing is rated IP67 standard.
6. درخواست جا منظر
قومي ريل پروجيڪٽ جي فراهمي جي هارڊ راڪ ڪواري | چيلنج: A granite quarry’s existing secondary crusher produced over 22% fines when making Type A ballast, creating a significant waste stream during a highvolume infrastructure project.| حل: Implementation of our HPCseries quarry ballast crushing equipment with a coarseliner chamber profile.| نتيجا: فين جي نسل کي ھيٺ گھٽائي ڇڏيو 14%, increasing saleable yield by over 8%. The automated wear compensation maintained gradation compliance across weekly quality audits with zero nonconformance reports.
Regional Aggregate Producer Expanding Market Reach | چيلنج: Need to produce both premium railway ballast and construction aggregate from the same plant without sacrificing flexibility or incurring excessive changeover downtime.| حل: Installation of our multichamber capable cone crusher with two interchangeable liner sets.| نتيجا: Changeover between rail spec aggregate and road base spec is achieved in one scheduled 8hour shift versus 24 hours previously required for major reconfiguration. This enabled the producer to service both markets competitively.
7. تجارتي خيالات
Our quarry ballast crushing equipment is offered in three primary tiers:
معياري فرض جي جوڙجڪ: For consistent feed materials. بنيادي کولہو شامل آهي, ڊرائيو موٽر, بنيادي lubrication نظام, and manual controls.
اعلي دستيابي جي جوڙجڪ: Adds automated wear compensation PLC system advanced dust seals heavyduty filtration package remote monitoring ports
Turnkey Modular Skid Package: Crusher premounted on a structural steel skid complete with integrated feeders conveyors walkways safety systems
اختياري خاصيتون شامل آهن:
Metal detection automatic tramp release systems
Lubrication oil condition sensors
ترقي يافته اڳڪٿي واري سار سنڀال سافٽ ويئر انضمام
Service packages range from annual inspection plans comprehensive longterm performance contracts including guaranteed parts availability financing options include equipment leasing capital loans through partner institutions tailored payperton agreements
8.FAQ
Q What primary crusher feed size is compatible with your quarry ballast crushing equipment?
A For optimal performance we recommend a maximum feed size not exceeding 250mm ideally prescreened at 40mm This ensures efficient operation prevents chokefeeding
Q How does this equipment impact our overall plant throughput?
A By increasing saleable yield reducing unplanned downtime field data typically shows net plant throughput increases between 5 15 depending on existing circuit limitations
Q ڇا لباس جا حصا آساني سان دستياب آهن?
A We maintain regional inventory hubs stock all critical wearing parts including mantles concaves bushings Standard delivery lead times are under 72 hours supported by guaranteed supply agreements
Q What are typical installation requirements?
A The unit requires prepared concrete foundations adequate craneage lifting capacity electrical connection per model specifications Our engineering team provides full foundation drawings load data
Q Can we finance this equipment under an operating expense OpEx model?
A Yes we offer several flexible arrangements including rental leasetoown contracts based on monthly throughput volumes allowing you preserve capital expenditure CapEx budgets
