Quarry Ballast Crushing Equipment Fabricator Datasheet
1. PAINPOINT driven اوپننگ
Are escalating operational costs and unpredictable downtime eroding your quarry's profitability in ballast production? عام چئلينج شامل آهن:
اعليٰ لباس & سار سنڀال جا خرچ: ابراھيندڙ گرينائيٽ, بيسالٽ, or limestone rapidly degrades crusher components, leading to frequent shutdowns and high parts replacement expenses.
متضاد پيداوار جي درجه بندي: Failure to meet strict railway or construction specifications (مثال, IN 13450) results in product rejection, ڇڪڻ واري چڪر, and wasted capacity.
گھٽ مجموعي نظام جي ڪارڪردگي: Bottlenecks between crushing stages, manual adjustments for feed variations, and excessive fines generation directly reduce tonsperhour output.
اضافي توانائي واپرائڻ: Inefficient crushing chambers and drives consume disproportionate power per ton of final product, هڪ اهم مقرر خرچ.
Is your current crushing circuit a source of constant adjustment and cost, rather than a reliable, اعلي پيداوار اثاثو? The solution lies in specifying equipment engineered explicitly for the sustained rigors of ballast production.
2. پيداوار جو جائزو
Our Quarry Ballast Crushing Equipment is engineered as a highcapacity, heavyduty primary or secondary crushing system designed to transform blasted rock into specification railway ballast and construction aggregate. The core workflow integrates:
1. ڪنٽرول ٿيل فيڊ: Scalping of subfines prior to crushing to reduce wear and improve efficiency.
2. HighReduction Crushing: Utilization of optimized cavity geometry to fracture rock along natural lines, maximizing yield of the desired 4070mm fraction.
3. Active Setting Regulation: Hydraulic adjustment systems allow quick response to feed changes to maintain consistent output gradation.
4. موثر خارج ٿيڻ: Optimized discharge conveyor design minimizes recirculation load and chip damage to finished product.
ايپليڪيشن جو دائرو: سخت پروسيسنگ لاء مثالي, abrasive igneous (گرينائيٽ, بيسالٽ) and metamorphic rock for highspecification ballast. حدون: Not designed for highly sticky, claybound materials or very soft sedimentary rock without significant circuit modification.
3. بنيادي خاصيتون
HeavyDuty روٽر & Concave سسٽم | ٽيڪنيڪل بنياد: Highinertia rotor design with interparticle crushing action | آپريشنل فائدا: Sustains higher throughput with lower tip speed, reducing wear energy cost by up to 15% روايتي ڊيزائن جي مقابلي ۾ | ROI اثر: Lower cost per ton through extended liner life and reduced specific energy consumption.
هائيڊرو سيٽ سي ايس ايس ايڊجسٽمينٽ | ٽيڪنيڪل بنياد: Hydraulic main shaft positioning system | آپريشنل فائدا: آپريٽرز کي اجازت ڏئي ٿي بند ٿيل سيٽنگ کي ترتيب ڏيڻ (سي ايس ايس) هيٺ 60 seconds for gradation control or to clear a stall | ROI اثر: Minimizes noncrushing downtime by over 90% for setting changes compared to manual shim systems.
لائنر ويئر مانيٽرنگ سسٽم | ٽيڪنيڪل بنياد: Ultrasonic sensor array integrated into crusher frame | آپريشنل فائدا: Provides realtime data on mantle and concave wear profiles, enabling predictive liner changes | ROI اثر: Eliminates unexpected liner failure downtime and allows full utilization of liner material, reducing waste by an estimated 20%.
Integrated Tramp Release & صاف ڪرڻ | ٽيڪنيڪل بنياد: Automatic hydraulic overload protection with reversing clearing cycle | آپريشنل فائدا: Safely passes tramp steel and uncrushable material, then resumes operation without manual intervention | ROI اثر: Prevents catastrophic damage to crusher components and avoids hours of dangerous manual cavity clearing.
ماڊلر لائنر ڊيزائن | ٽيڪنيڪل بنياد: Segmented concave sections with common bolt patterns | آپريشنل فائدا: Reduces liner changeout time by utilizing smaller, manageable components; safer for maintenance crews | ROI اثر: منصوبابندي ڪيل سار سنڀال جو وقت گھٽائي ٿو 40%, سالياني دستياب پيداوار جا ڪلاڪ وڌائڻ.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (سراسري مخروط کولہو) | اسان جي ballast ڪرشنگ حل | فائدو (% سڌارو) |
| : | : | : | : |
| لائنر زندگي (ابراھيندڙ گرينائيٽ) | 450,000 550,000 ٽين | 600,000 750,000 ٽين | +25% جي طرف +35% |
| مخصوص توانائي واپرائڻ| 0.8 1.1 kWh/ٽن | 0.65 0.85 kWh/ٽن| 20% سراسري طور تي |
| درجه بندي مطابقت (SD of % لنگھندڙ چاٻي)| اعلي تبديلي (±8%)| سخت ڪنٽرول (±3%)| Improved consistency by >60% |
| ناڪامي جي وچ ۾ وچولي وقت (ايم بي ايف) – Mechanical| ~ 1,200 ڪلاڪ| >1,800 ڪلاڪ| +50% اعتبار |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 300 ختم ڪرڻ 1,200 ميٽرڪ ٽين في ڪلاڪ تيار ٿيل بيلسٽ پراڊڪٽ.
بجلي جي گهرج: مکيه کولہو ڊرائيو کان 200 kW تائين 500 ڪلواٽ; ڪل پلانٽ معاون طاقت جو دارومدار ترتيب تي.
مواد جي وضاحت: Constructed from highstrength alloy steel (فريم); mantles and concaves available in multiple grades of manganese steel (Mn18Cr2 standard) or optional chromewhiteiron alloys for extreme abrasion.
فيڊ سائيز جي قبوليت: تائين 90% of crusher feed opening dimension (typically up to ~250mm).
جسماني طول و عرض (عام پرائمري يونٽ): لڳ ڀڳ. ڊگھائي: ~5 م; ويڪر: ~ 3 م; اوچائي: ~ 3.5m; وزن: ~4570 tonnes.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; dustsealed بيرنگ; اختياري گرمائش / کولنگ پيڪيجز موجود آهن.
6. درخواست جا منظر
Railway Ballast Production Plant – Scandinavia
چيلنج: A granite quarry supplying national rail networks faced excessive wear costs and fines generation exceeding the strict <1% specification with their existing jawcone circuit.
حل: Implementation of a primary gyratory crusher followed by a secondary cone crusher specifically configured for ballast production.
نتيجا: Fines generation was reduced by over 50%, consistently meeting EN spec. لائنر جي زندگي وڌي وئي 30%, دستاويز ۾ حصو وٺڻ 18% reduction in cost per ton of saleable ballast.
Integrated Aggregates & Ballast Quarry – North America
چيلنج: Need for flexible production switching between road base aggregates (smaller sizes) and largesize railway ballast led to frequent circuit reconfiguration and lost shifts.
حل: Installation of a multicylinder cone crusher with rapid Hydroset adjustment capabilities.
نتيجا: Changeover between product specifications is now achieved in under 10 minutes via automated settings adjustment versus a previous 4hour mechanical shift change process.
7. تجارتي خيالات
قيمت جا درجا: Equipment is offered in three capability tiers—Standard Duty (for consistent feed), ڳري ڊيوٽي (انتهائي ٻرندڙ پٿر لاء), and Extreme Duty (for maximum uptime requirements)—with corresponding capital investment levels.
اختياري خاصيتون: ترقي يافته خودڪار پيڪيجز (ASRi), dust suppression integration kits specialized lubrication cooling systems remote monitoring telematics
سروس پيڪيجز: Choose from Basic Warranty Extended Component Assurance Plans or Comprehensive Total Care Agreements covering parts labor scheduled inspections
فنانسنگ جا اختيار: Flexible capital solutions include equipment leasing longterm rental with service inclusion traditional purchase Project financing support can be arranged
8. FAQ
Q1 Is this equipment compatible with our existing primary jaw crusher screening plant?
Yes Our ballast crushing units are designed as modular replacements or upgrades within existing circuits Standard discharge heights conveyor interface points power connection types ensure integration is straightforward
Q2 What is the typical installation commissioning timeframe?
For a standalone secondary tertiary unit installation commissioning typically requires 1421 days depending on foundation readiness Full plant system integration naturally requires more extensive planning
Q3 How does this solution impact our operational manpower requirements?
The automation reliability features are designed to reduce manual intervention Field data shows clients often reassign one operator role previously dedicated constant crusher monitoring other valueadded tasks
Q4 ادائگي جون شرطون ليڊ ٽائيم ڇا آهن?
Standard commercial terms involve progress payments against manufacturing milestones Lead times range from 26 weeks for standard configurations up 40 weeks fully customized plants subject current order backlog
Q5 Can you provide material testing specific crushability work index data?
Yes Our engineering team can conduct presale analysis your quarry samples provide detailed projections throughput gradation curves wear rates based proprietary simulation models
