صنعتي هارگا هيمر مل اسيمبلي پلانٽ
1. PAINPOINT driven اوپننگ
Are you managing a mineral processing or aggregate production line where consistent particle size reduction is critical? Operational bottlenecks at the primary crushing stage directly impact your entire downstream process, leading to measurable losses. عام چئلينج شامل آهن:
غير منصوبا بند وقت: Frequent component failure in highwear areas like hammers and liners halts production. Industry data indicates that for a midsized plant, every hour of unplanned downtime can cost over $2,500 in lost output and labor.
غير متضاد آئوٽ پٽ گريڊيشن: Variable feed material leads to an offspec product, causing recirculation loads that waste energy and reduce system throughput by 1530%.
اضافي آپريشنل خرچ: Rising energy consumption per ton processed and the high frequency of wear part replacement erode profit margins.
سار سنڀال جي پيچيدگي: Timeconsuming, laborintensive assembly and alignment of hammer mill rotors increase mean time to repair (ايم ٽي آر), keeping your asset offline longer.
Is your current size reduction solution contributing to these costs? What if your hammer mill assembly was engineered for resilience, درستي, and faster serviceability?
2. پيداوار جو جائزو: Industrial HeavyDuty Hammer Mill Assembly Plant
هي حل هڪ مڪمل ڏانهن اشارو ڪري ٿو, preengineered hammer mill system designed for continuous, hightonnage industrial operations. It integrates the core size reduction unit with optimized feed and discharge systems, مٽي ڪنٽرول, and quickaccess maintenance features.
آپريشنل ڪم فلو:
1. ڪنٽرول ٿيل فيڊ: Incoming raw material (مثال, چونا پٿر, ڪوئلو, ٻيهر استعمال ٿيل مجموعا) is metered via an adjustable feeder onto the rotor assembly.
2. اثر گھٽائڻ: A highinertia rotor with dynamically balanced hammers impacts material against a rigid manganese steel breaker plate, achieving initial fracture.
3. ماپ ڪنٽرول: Particles are further reduced through attrition against the screen grate; final product size is determined by grate opening dimensions.
4. موثر خارج ٿيڻ: Sized material passes through the grates and is conveyed away by an integrated system, while oversize material remains for further reduction.
ايپليڪيشن جو دائرو: Primary and secondary crushing of nonabrasive to moderately abrasive materials with compressive strengths below 150 ايم پي اي. Ideal for cement plants, aggregate quarries, coal processing, ۽ ري سائیکلنگ جون سهولتون.
حدون: انتهائي خرابي واري مواد لاء مناسب ناهي (مثال, سليڪا واري ريت) without significant operational cost adjustments or for processing ductile metals.
3. بنيادي خاصيتون
Monobloc Rotor Assembly | ٽيڪنيڪل بنياد: Singlepiece forged steel shaft with integrally cast disc design | آپريشنل فائدا: Eliminates disctoshaft fretting and bolt failure points; ensures permanent dynamic balance under load | ROI اثر: Reduces vibrationrelated bearing failures by up to 40%, extending service intervals
QuickSwitch Hammer & Grate System | ٽيڪنيڪل بنياد: Hydraulically assisted access doors and cartridgestyle wear part holders | آپريشنل فائدا: Enables full set of hammer or grate changeout in under 4 hours with a standard crew | ROI اثر: Cuts downtime for routine wear maintenance by approximately 60% compared to bolted designs
Asymmetric Crushing Chamber Design | ٽيڪنيڪل بنياد: Optimized chamber geometry directs material flow into the impact zone | آپريشنل فائدا: فرسٽ پاس گھٽائڻ جو تناسب وڌائي ٿو, minimizing recirculation and power draw per ton | ROI اثر: فيلڊ ڊيٽا ڏيکاري ٿو a 1218% improvement in throughput efficiency at equivalent motor ratings
حالت مانيٽرنگ پورٽ | ٽيڪنيڪل بنياد: Integrated sensor mounts (وائبريشن, گرمي پد) at bearing housings and rotor shaft | آپريشنل فائدا: Enables predictive maintenance scheduling based on actual component condition | ROI اثر: تباهي واري ناڪامي کي روڪي ٿو; allows parts ordering aligned with planned outages
HeavyDuty Baseframe with Dampening | ٽيڪنيڪل بنياد: Laminated steel frame with antivibration pads engineered to specific harmonic frequencies | آپريشنل فائدا: Absorbs operational shocks, protecting auxiliary equipment and foundation integrity | ROI اثر: Lowers structural maintenance costs and reduces noise emission levels
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | Our Hammer Mill Assembly Solution | فائدو (% سڌارو) |
| : | : | : | : |
| ناڪامي جي وچ ۾ وچولي وقت (ايم بي ايف) روٽر اسيمبلي| 1,200 1,800 ڪلاڪ | 2,700+ ڪلاڪ (دستاويز ٿيل) | +50% |
| مخصوص توانائي واپرائڻ (kWh/ٽن) for 25mm product| 1.8 2.2 kWh/ٽن| 1.5 1.7 kWh/ٽن| ~1520% Reduction |
| لباس جو حصو مٽائڻ وقت (Full Set Hammers)| 6 8 ڪلاڪ| 40% تيز |
| شور جي اخراج تي 1 ميٽر| ~105 dBA| ~92 dBA| >10% گھٽتائي |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 150 TPH کان مٿي 800 ٽي پي ايڇ, مادي خاصيتن تي منحصر آهي.
بجلي جي گهرج: مکيه ڊرائيو موٽر کان 400 kW کان 1250 ڪلواٽ, compatible with VFDs for softstart capability.
مواد جي وضاحت:
Rotor Shaft/Discs: Forged AISI 4140 اسٽيل
هٿيار & ٽوڙيندڙ پليٽون: Martensitic ڪروم اسٽيل (500+ بي ايڇ اين)
Screen Grates: Abrasion Resistant اسٽيل (400 بي ايڇ اين), customizable openings from 3mm to 75mm.
هائوسنگ & لينر: AR400 Liner Plates with bolton replaceable sections.
جسماني طول و عرض (Model HMA450): لڳ ڀڳ. ڊگھائي: .5m x Width .8m x Height .6m (فيڊ / خارج ٿيڻ کان سواء).
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 50 ° C تائين محيطي درجه حرارت لاء ٺهيل; dustproofed to IP65 standards on critical bearings.
6. درخواست جا منظر
سيمينٽ پلانٽ جي خام مال جي تياري | چيلنج: A plant experienced weekly downtime due to cracked hammer rods on their limestone crusher, causing inconsistent kiln feed chemistry and costly interruptions.| حل: Installation of our hammer mill assembly featuring the monobloc rotor and quickswitch hammer system.| نتيجا: Rotorrelated unplanned stops were eliminated. Scheduled wear part changes were completed in one shift instead of two. Plant reported a .7% improvement in kiln thermal consistency due to more uniform feed size.
اڏاوت & ڊيموليشن ويسٽ ري سائيڪلنگ | چيلنج: پروسيسنگ متغير C&D waste led to rapid clogging of crusher grates and excessive wear from hidden contaminants like rebar.| Solution Implementation of an asymmetric chamber hammer mill assembly with heavyduty,tramptolerant grates.| Results Throughput of mixed debris increased by .5%. Downtime for clearing jams decreased by .0%. Wear part life on hammers improved by % due to better material flow reducing metalonmetal contact.
7. تجارتي خيالات
Our industrial hammer mill assembly solutions are offered in three primary tiers:
1. بنيادي ٺاھ جوڙ جو درجو: Includes core hammer mill assembly with standard rotor,برقي موٽر ڊرائيو,and starter.Focuses on reliability at a competitive capital cost.
2.
3.ڪارڪردگي جو درجو (سڀ کان عام): Adds the quickswitch maintenance system,VFD soft start,vibration مانيٽرنگ سينسر,and upgraded wear material options.Balances operational efficiency with lifecycle cost management.
4.پريميئم پلانٽ انٽيگريشن ٽائر: Fully skidded system including integrated feed conveyor,مقناطيسي جدا ڪندڙ,مٽي کي دٻائڻ واري انگوزي,and PLC control panel.Ready for connection to plant utilities.
اختياري خاصيتن ۾ شامل آهن خودڪار لوبريڪيشن سسٽم,custom screen grate configurations,and spare part kits.Service packages range from basic commissioning support to comprehensive annual inspection contracts.Financing options including equipment leasing are available through our partners.
8.FAQ
ق:What is the lead time for delivery of a complete hammer mill assembly?
A Lead times vary by model tier.For Performance Tier configurations standard lead time is weeks from order confirmation subject to project scope
Q Can this system be integrated into our existing crushing circuit?
A Yes Our engineering team provides interface drawings for chute work conveyor connections electrical hookups based on your plant layout ensuring compatibility
Q What is the expected operational lifespan of the main rotor assembly?
A Under normal operating conditions industry testing demonstrates the monobloc rotor has a design life exceeding years before major refurbishment may be required
Q How does this solution impact our overall plant energy consumption?
A The combination of high inertia rotor efficient chamber design reduces specific energy consumption Field data shows plants typically record a net reduction in total circuit power draw despite increased throughput
Q ڇا لباس جا حصا آساني سان دستياب آهن?
A We maintain regional inventory hubs All key wearing components are standardized across our model range ensuring availability Critical parts can be shipped within hours under our premium service plan
Q What commercial terms are offered?
A We provide firm FOB pricing Standard payment terms are % حڪم تي % before shipment Balance due upon delivery Extended terms may be available subject to credit approval
