Quarry ballast ڪرشنگ سامان جي پيداوار Quotation
1. PAINPOINT driven اوپننگ
آپريشنل خرچن ۾ اضافو ڪري رهيا آهن ۽ غير متوقع وقت ختم ڪري رهيا آهن توهان جي کواري جي منافعي کي? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, مسلسل پيداوار, highquality railway ballast presents distinct challenges. نامناسب فيڊ مواد جي ڪري وڌ ۾ وڌ جرمانه پيدا ٿئي ٿو, سخت ذرات جي ماپ جي ورڇ ۾ ناڪامي (پي ايس ڊي) specifications and resulting in product rejection. Frequent liner wear in crushing chambers increases maintenance intervals, causing costly production halts. High energy consumption per ton of final product directly impacts your bottom line. ان کان سواء, the need for multiple crushing stages to achieve the cubical shape required for optimal track bed stability often complicates plant layout and increases capital expenditure.
How do you increase yield of specification ballast while controlling wear costs and energy use? The efficiency of your primary crushing stage is fundamental to solving these problems.
2. پيداوار جو جائزو
هي پراڊڪٽ لائن ڳري ڊيوٽي تي مشتمل آهي, stationary primary jaw crushers engineered specifically for highvolume quarry ballast production. The operational workflow is designed for maximum reliability: (1) روم (RunofMine) feed is delivered to the vibrating grizzly feeder, which removes natural fines and bypasses subsize material; (2) Oversize material is directed into the deep crushing chamber of the jaw crusher for initial compression breaking; (3) The crushed material is discharged onto a main conveyor at a consistent, optimized size for secondary processing. This equipment is designed for hard rock applications (گرينائيٽ, بيسالٽ, پٿر جو پٿر) اعلي abrasiveness سان. It is not suited as a standalone solution for soft or highly friable rock without secondary shaping stages.
3. بنيادي خاصيتون
جارحتي ڪرشنگ جاميٽري | ٽيڪنيڪل بنياد: Steep nip angle and long stroke | آپريشنل فائدا: Generates higher throughput and effective size reduction in a single pass, reducing load on downstream cone crushers. | ROI اثر: Increases total plant capacity by 1015%, اثاثن جي استعمال کي وڌائڻ.
HeavyDuty فريم تعمير | ٽيڪنيڪل بنياد: Fabricated steel plate with reinforced ribbing and stressrelieved welding. | آپريشنل فائدا: ناقابل برداشت مواد مان جھٽڪو لوڊ ڪرڻ جي خلاف غير معمولي استحڪام فراهم ڪري ٿو, فريم جي ٿڪ کي گھٽائڻ ۽ تباهي واري ناڪامي جو خطرو. | ROI اثر: ڍانچي جي خدمت جي زندگي کي وڌايو 20 عام آپريشن هيٺ سال, سرمائيداري سيڙپڪاري جي حفاظت.
ماڊلر لائنر سسٽم | ٽيڪنيڪل بنياد: Interchangeable cheek plate and jaw die segments secured by wedgelocking mechanisms. | آپريشنل فائدا: Reduces replacement downtime from days to hours. Allows strategic rotation of wear parts to utilize full material volume. | ROI اثر: Cuts liner changeout labor costs by up to 40% ۽ کولہو جي دستيابي کي وڌائي ٿو.
هائيڊولڪ ايڊجسٽمينٽ & صاف ڪرڻ | ٽيڪنيڪل بنياد: Integrated hydraulic cylinders for setting adjustment and clearing tramp metal/uncrushables. | آپريشنل فائدا: CSS جي ريموٽ ايڊجسٽمينٽ کي فعال ڪري ٿو (بند طرف سيٽنگ) for quick product gradation changes and safe, rapid clearing of blockages without manual intervention. | ROI اثر: غير منصوبابندي ٿيل اسٽاپ کي گھٽ ڪري ٿو; فيلڊ ڊيٽا ڏيکاري ٿو a 90% reduction in downtime related to chamber blockages.
سڌو ڊرائيو & Flywheel Design | ٽيڪنيڪل بنياد: Hightorque motor coupled directly to eccentric shaft with optimized flywheel mass. | آپريشنل فائدا: Ensures consistent power transmission under peak loading conditions, maintaining constant velocity for improved particle shaping. | آپريشنل فائدا: Improves energy efficiency by reducing transmission losses common in Vbelt drives.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | کواري ballast ڪرشنگ حل | فائدو (% سڌارو) |
| : | : | : | : |
| لائنر زندگي (ابراھيندڙ پٿر)| 450,000 550,000 ٽين| 600,000 750,000 ٽين| +25% سراسري |
| توانائي جو واھپو| 0.85 1.1 kWh/ٽن| 0.72 0.90 kWh/ٽن| تائين 18% گهٽتائي |
| Cubical Product Yield| ~65% postprimary| ~75% postprimary| +10 سيڪڙو پوائنٽون |
| سار سنڀال جي وچ ۾ وچولي وقت (ايم بي ايم)| ~ 450 ڪلاڪ| ~600 hours| +33% |
| ذريعي پٽ مطابقت| +/ 15% variance during shift|< +/ 8% variance during shift| Variance reduced by nearly half |
5.ٽيڪنيڪل وضاحتون
گنجائش جي حد: 500 1,800 MTPH (فيڊ مواد ۽ CSS تي منحصر آهي)
فيڊ کولڻ: 60 "x 80" تائين (1,500mm x 2,000mm)
بجلي جي گهرج: 200 400 kW electric drive
مواد جي وضاحت: ASTM A36 اسٽيل مان ٺهيل; Jaw dies available in AR400 or manganese steel (1822%); شافٽ اعلي طاقت مصر فولاد مان ٺهيل.
اهم جسماني طول و عرض: Approximate weight range from 85,000 ڪلو تائين 165,000 ڪلو.
ماحولياتي آپريٽنگ رينج: مناسب لوبريڪيشن سسٽم سان گڏ 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل.
6. درخواست جا منظر
Granite Quarry – Railway Ballast Supply Contract
چيلنج: A national rail project required consistent Grade A ballast supply at over 800 Mtph but faced frequent jaw crusher liner failures every six weeks due to highly abrasive granite.
حل: Implementation of a primary jaw crusher featuring the modular liner system in manganese steel.
نتيجا: Liner life extended to nine weeks per set while maintaining target throughput quantifiable outcomes included a direct reduction in wear part costs of $135k annually and a projected increase in annual production hours due to fewer changeouts.
Basalt Aggregate Producer – Plant Modernization
چيلنج: An existing plant’s primary crusher produced excessive flaky material requiring additional processing stages poor particle shape reduced final ballast yield.
حل: Replacement with a new primary jaw crusher engineered with aggressive geometry and optimal stroke.
نتيجا: Postprimary cubical product yield increased from an average of production data confirmed an overall plant yield improvement allowing the contractor to fulfill two concurrent supply contracts without expanding secondary crushing capacity.
7. تجارتي خيالات
Pricing tiers are structured based on crusher size feed opening capacity:
Tier I Standard Duty Configuration includes crusher motor drives basic guarding installation drawings
Tier II BallastOptimized Package adds hydraulic adjustment overflow chute specialized jaw die profile extended warranty
Tier III Turnkey Skid Module includes feeder scalping screen integral walkways ladders preassembled electricals
Optional features include automated lubrication systems wear monitoring probes dust suppression ring guards
Service packages are available as Bronze Silver Gold levels covering parts labor scheduled inspections Financing options include capital lease operating lease or projectbased financing terms typically ranging from months
8. FAQ
What upstream equipment is needed?
A vibrating grizzly feeder is strongly recommended ahead of this crusher scalp out fines protect the chamber from unnecessary wear ensure even feed distribution across the jaw length
Can this equipment process recycled concrete or asphalt?
While capable it is not optimal design focuses on hard virgin rock using it for recycling may accelerate wear due to contaminants lower ROI compared dedicated recycling impactors
تنصيب جون عام ضرورتون ڪهڙيون آهن?
Requires substantial reinforced concrete foundation detailed foundation drawings provided lead time from order commissioning averages months depending model site conditions
How does pricing compare total cost ownership TCO?
Initial investment may be higher than standard models however industry testing demonstrates lower TCO over year period due reduced energy consumption extended wear part life higher availability
What training provided operators maintenance staff?
Comprehensive onsite training covers safe operation routine maintenance troubleshooting procedures detailed manuals video libraries accessible
