ڪوارري بيلسٽ کرشنگ سامان خانگي ليبل ٺاهيندڙ نموني
ھدف ٿيل ڪواري بيلسٽ کرشنگ حل: انجڻ جي ذريعي, اسپيڪ, ۽ CostPerTon
1. PAINPOINT driven اوپننگ
مسلسل پيداوار, specificationgrade ريلوي ballast هڪ نازڪ اڃان مطالبو آپريشن آهي. نامناسب کاڌو مواد, ڇڪڻ وارو پٿر, and stringent gradation requirements create persistent challenges that directly impact your bottom line. ڇا توهان کي منهن ڏيڻو آهي:
زيادتي پائڻ & غير منصوبا بند وقت: Are premature liner failures and component wear in your secondary/tertiary stage causing costly, unscheduled shutdowns and ballooning parts inventories?
OffSpec Product & پيداوار جو نقصان: Is a significant portion of your output failing to meet the strict particle shape (ڪعبي) and size distribution (درجه بندي) required for rail ballast, forcing material to be recrushed or downgraded?
اعلي آپريشنل خرچ: Are your energy consumption per ton and maintenance labor hours exceeding projections, eroding profit margins on every cubic meter of ballast shipped?
غير لچڪدار پيداوار: Does your current circuit struggle to maintain optimal performance with varying feed sizes or rock hardness, requiring constant manual adjustment and risking spec deviation?
جيڪڏهن اهي آپريشنل رڪاوٽون واقف آهن, the selection of your tertiary or quaternary crushing stage is not just an equipment purchase—it’s a strategic decision determining plant profitability.
2. پيداوار جو جائزو: HIGHPERFORMANCE CONE CRUSHER FOR BALLAST PRODUCTION
This solution centers on a heavyduty cone crusher specifically configured for the final shaping and sizing stages in quarry ballast production. Engineered to transform secondary crushed aggregate into precise, highintegrity railway ballast.
آپريشنل ڪم فلو:
1. ڪنٽرول ٿيل فيڊ: Correctly sized feed from secondary crushing (typically 80mm) is introduced via a regulated feeding system.
2. InterParticle Communition: The rock is compressed and crushed multiple times between the mantle and concave liners within a packed crushing chamber.
3. درست ماپ ڪنٽرول: The crusher’s hydraulic adjustment system allows realtime control of the closedside setting (سي ايس ايس), آخري پراڊڪٽ جي مٿين سائيز جو تعين ڪرڻ.
4. مسلسل خارج ٿيڻ: ڪٽيل مواد چيمبر مان نڪرندو آهي, achieving the required cubicity for optimal interlock and drainage in rail applications.
ايپليڪيشن جو دائرو & حدون:
لاء مثالي: Tertiary or quaternary reduction of granite, بيسالٽ, پٿر جو پٿر, ۽ ٻيو سخت, abrasive aggregates to produce 2850mm or 31.563mm standard railway ballast.
حدون: نه ٺهيل آهي هڪ بنيادي کولہو جي طور تي runofquarry مواد لاء. Maximum feed size is dependent on model selection but typically does not exceed 80120mm for optimal ballast production.
3. بنيادي خاصيتون
ترقي يافته چيمبر ڊيزائن | ٽيڪنيڪل بنياد: Laminated crushing principle with optimized kinematics | آپريشنل فائدا: Promotes interparticle crushing to produce a consistent output with superior particle shape (اعلي ڪعبي) and fewer elongated/flaky particles. | ROI اثر: Increases saleable ballast yield by an average of 815%, reducing waste and recirculating load.
هائيڊولڪ سيٽنگ جي ترتيب (ايڇ ايس اي) سسٽم | ٽيڪنيڪل بنياد: Remote hydraulic control of the crusher’s closedside setting (سي ايس ايس) لوڊ هيٺ. | آپريشنل فائدا: Allows operators to make precise CSS adjustments in under one minute without stopping the crusher to compensate for wear or change product spec. | ROI اثر: تائين جي ترتيبن لاءِ دير جو وقت گھٽائي ٿو 90% دستي شيم سسٽم جي مقابلي ۾, سڌو سنئون پلانٽ جي دستيابي کي وڌائڻ.
AntiSpin & Head Speed Control | ٽيڪنيڪل بنياد: Patented mechanism that limits the spin of the mantle to prevent uncontrolled rotation at noload or lightload conditions. | آپريشنل فائدا: Reduces liner wear evenly and decreases power spikes during startup or empty chamber conditions. | ROI اثر: تائين لائنر جي زندگي کي وڌايو 30%, lowering consumable costs per ton and stabilizing energy consumption.
خودڪار ڪنٽرول سسٽم (ACS) انضمام | ٽيڪنيڪل بنياد: PLCbased system monitoring critical parameters like power draw, دٻاءُ, غار جي سطح, ۽ CSS. | آپريشنل فائدا: Provides realtime data and can automatically regulate feed rate or perform corrective actions to protect the crusher from overloads and maintain optimal performance. | آپريشنل فائدا: Protects major components from damage due to tramp metal or uncrushables through rapid hydraulic release and reset.
HeavyDuty بيئرنگ & مين فريم جي تعمير | ٽيڪنيڪل بنياد: Largediameter spherical roller bearings supported within a fabricated steel mainframe of highstrength plate. | آپريشنل فائدا: Provides high radial load capacity for continuous heavyduty operation with hard abrasive rock common in ballast quarries.| ROI اثر: Ensures longterm structural integrity and reliability, minimizing risk of catastrophic failure that leads to extended outages.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | Industry Standard Baseline | Our Ballast Cone Crusher Solution | دستاويزي فائدو |
| : | : | : | : |
| لائنر ڪپڙا زندگي (ابراھيندڙ پٿر) | Reference = 100% (مثال, 450k ٽين) | Utilizes proprietary manganese steel chemistry & ڪمري جي جوڙجڪ | +25% جي طرف +35% increased tonnage per liner set |
| طاقت جي ڪارڪردگي (kWh/ٽن) | Reference = 100% | آپٽمائزڊ ڪينيميٽيڪس & antispin technology reduce noload losses| تائين 10% مخصوص توانائي جي استعمال ۾ گهٽتائي |
| پيداوار جي ڪعبي (% تناسب) | Typical cone output (~7580% cubic)| Advanced chamber geometry promotes interparticle breakage| مسلسل حاصل ڪري ٿو >85% cubicity meeting stringent rail specs |
| دستيابي (% اپٽائم) | Excludes planned maintenance stops| Hydraulic setting adjustment & robust design reduce unplanned stops| فيلڊ ڊيٽا ڏيکاري ٿو >96% mechanical availability in ballast duty |
| ترتيب ڏيڻ جو وقت (منٽ)| دستي شيم سسٽم (~6090 min)| Hydraulic Setting Adjustment under load (<2 منٽ)| Downtime reduction exceeding 95% |
5. ٽيڪنيڪل وضاحتون
ماڊل رينج جي گنجائش: 120 - 550 ميٽرڪ ٽين في ڪلاڪ تيار ٿيل بيلسٽ پراڊڪٽ (dependent on closedside setting and material characteristics).
بجلي جي گهرج: مکيه کولہو ڊرائيو کان 132 kW تائين 315 ڪلواٽ (200 - 500 ايڇ پي). Hydraulic system requires additional auxiliary power.
مواد جي وضاحت: Engineered for maximum feed size of ≤80mm (120mm optional). Constructed with highstrength steel mainframe; concaves/mantles in premiumgrade manganese steel (M2/M7).
جسماني طول و عرض / وزن: ماڊل جي لحاظ کان مختلف آهي; approximate footprint range of 3m x 2m up to 5m x 4m; weights from ~15 tonnes up to ~35 tonnes.
ماحولياتي آپريٽنگ رينج: Standard design operates in ambient temperatures from 20°C to +40°C (4°F کان +104°F). Optional heating/cooling packages available for extreme climates.
6. درخواست جا منظر
نيشنل ريل نيٽ ورڪ جي فراهمي گرينائيٽ ڪواري
چيلنج: A major quarry's existing tertiary cone crushers produced excessive fines (<22ايم ايم) and elongated particles when producing Type A Ballast (31.563ايم ايم), ڏانهن وٺي وڃي ٿو a 20% yield loss as material was rejected or reprocessed.
حل: Implementation of two specialized cone crushers configured with a "ballastoptimized" crushing chamber profile.
نتيجا: Product cubicity improved from an average of 78% جي طرف +87%. Saleable ballast yield increased by 18%, effectively adding significant revenue from existing reserves without increasing blast volume.
Regional Aggregate Producer Adding Rail Ballast Line
چيلنج: A contractor needed a compact tertiary circuit capable of switching between concrete aggregate (22ايم ايم) ۽ ريلوي ballast (50ايم ايم) production without lengthy changeover periods.
حل: Installation of a single multipurpose cone crusher equipped with Hydraulic Setting Adjustment (ايڇ ايس اي).
نتيجا: Changeover between product settings is now achieved in under five minutes via the control panel versus a previous twohour manual process on older equipment, providing exceptional operational flexibility.
7. تجارتي خيالات
Our quarry ballast crushing equipment is offered through flexible commercial models designed for capital planning:
سامان جي قيمت جا درجا: Based on model capacity (+/200tph / +/400tph / +500tph+) with corresponding levels of standard automation.
اختياري خاصيتون / پيڪيجز:
ترقي يافته آٽوميشن پيڪيج (full ACS with feed control integration)
لائنر ويئر مانيٽرنگ سسٽم
Dust Sealing Package
360degree Maintenance Platform
HighAmbient or ColdClimate Kits
خدمت & سپورٽ پيڪيجز: Available as annual contracts covering scheduled inspections, ترجيحي حصن جي ترسيل (+24/48hr options), technical support access.
فنانسنگ جا اختيار: We work with accredited partners able provide equipment leasing structures tailored typical mining/aggregate project cash flows
FAQ
1.Q What upstream equipment configuration works best feeding this cone crusher for ballast?
A For optimal results we recommend feeding it screened overflow from secondary stage typically jaw impactor This ensures consistent well distributed choke fed conditions maximize particleonparticle breakage
2.Q How does this solution handle occasional uncrushable material tramp metal?
A The integrated overload protection system utilizes hydraulic cylinders support mainshaft It allows temporary opening discharge pass uncrushable then automatically returns original setting without stopping process
3.Q What typical lead time expected major wear parts mantles concaves?
A We maintain strategic regional inventory critical consumables Standard manganese liners typically available exstock within region Customized profiles may require longer lead time based production schedule
4.Q Can existing plant PLC control system integrate new crushers automation?
A Yes Our control systems designed communicate via standard industrial protocols Modbus TCP/IP Profibus etc allowing central control room monitor adjust key parameters
5.Q What key factors determine correct model selection our operation?
A Primary factors are required finished product capacity tph desired CSS range type hardness abrasiveness feed material Detailed application review our engineering team recommended ensure fit
6.Q ڪارڪردگي جي ضمانت ڏني وئي آهي?
A Yes We offer guaranteed capacity throughput based agreed test protocol specific material Guarantees also cover mechanical availability provided recommended maintenance schedules followed
7.سوال اسان جي آپريشن جي سار سنڀال جي عملي کي ڪهڙي تربيت ڏني?
A Comprehensive commissioning training included covers safe operation daily checks basic troubleshooting procedures Maintenance training focuses liner change procedures system diagnostics optional advanced sessions available
