Crushing And Screening Equipment Producers Cheap
1. HAPJE NGA PIKA E DIKIMIT
Po përshkallëzimi i kostove operacionale dhe koha e paparashikueshme e joproduktive po gërryen marzhet e projektit tuaj? Për menaxherët e impianteve dhe kontraktorët inxhinierikë, qarku i shtypjes dhe i skanimit është shpesh burimi i pengesave kritike. Sfidat e zakonshme përfshijnë:
Kostot e larta të mirëmbajtjes: Frequent bearing failures, screen cloth changes, and conveyor belt wear from improper material flow can consume 1520% of your annual operating budget.
Kohë joproduktive të paplanifikuara: A primary crusher failure or screen box structural issue can halt an entire site, costing tens of thousands per hour in lost production and labor.
Inefficient Material Flow: Poorly matched equipment leading to recirculating loads, chokefeeding, or underutilization reduces overall system capacity by up to 30%.
Gradim i paqëndrueshëm i produktit: Offspec aggregate or mineral product results in costly recrushing, stockpile segregation issues, and rejected loads.
Rritja e Konsumit të Energjisë: Older, mechanically inefficient drives and components directly increase your kWhperton cost, a key metric under constant pressure.
Is your operation equipped to minimize these risks while maximizing throughput and product quality? The foundation lies in selecting robust, intelligently engineered pajisjet e shtypjes dhe skanimit.
2. PËRMBLEDHJE E PRODUKTIT
This content outlines the critical considerations for stationary and trackmounted pajisjet e shtypjes dhe skanimit, the core machinery for reducing raw feed material (p.sh., quarry rock, beton i ricikluar, mineral ore) në madhësi të caktuara të agregatit. Rrjedha e punës operacionale është një proces i vazhdueshëm:
1. Reduktimi i madhësisë primare: Large feed material is reduced by jaw or gyratory crushers.
2. Material Transport & Skalping: Conveyors move material to vibrating screens that remove undersize material prior to secondary crushing.
3. Thërrmimi sekondar/terciar: Cone or impact crushers further reduce material to required dimensions.
4. Shfaqja përfundimtare & Renditja: Multideck screens accurately separate crushed material into precise product fractions (p.sh., ¾” chip, rërë e prodhuar).
5. Grumbullimi i rezervave & ReCirculation: Onspec product is conveyed to stockpiles; oversize material is recirculated back into the circuit.
Fusha e aplikimit përfshin guroret, minierave, ndërtimi & riciklimi i prishjes, dhe prodhimi agregat. Key limitations involve feed material abrasiveness (impacting wear life) dhe specifikimet e kërkuara të produktit përfundimtar (dictating circuit design).
3. TIPARET THEMELORE
Gjeometria e dhomës e patentuar | Baza Teknike: Computermodeled kinematics and cavity profiles | Përfitimi Operacional: Optimized nip angle and crushing stroke for higher reduction ratios with less wear on manganese surfaces | Ndikimi i ROI: Deri në 12% lower costperton in abrasive applications due to extended liner life.
Modular Screen Media System | Baza Teknike: Quicktensioning wedgelock design with polyurethane damping | Përfitimi Operacional: Screen deck changes completed in under 2 hours versus a typical 68 hour shift, with consistent tension for longer cloth life | Ndikimi i ROI: Reduces labor hours for maintenance by ~70% per changeout, rritja e disponueshmërisë së impiantit.
Grasimi i centralizuar & Monitorimi i gjendjes | Baza Teknike: Automated lube points with flow sensors feeding a central PLC | Përfitimi Operacional: Ensures critical crusher and screen bearings receive precise lubrication without manual intervention; alerts operators to blockages | Ndikimi i ROI: Prevents an estimated 85% of bearingrelated failures, avoiding associated downtime costs.
Hybrid Power Drive System | Baza Teknike: Dieselelectric configuration with onboard genset or external grid connection capability | Përfitimi Operacional: Operators can select the most costeffective power source; electric mode reduces fuel consumption by 100% when grid power is available | Ndikimi i ROI: Field data shows average energy cost savings of 2540% in hybrid mode versus dieselonly operation.
HeavyDuty Feeder with PreScreening Section | Baza Teknike: Grizzly feeder with integrated stepped grizzly bars or punch plate section | Përfitimi Operacional: Removes natural fines and subproduct size material before the primary crusher, reducing chamber volume usage and wear | Ndikimi i ROI: Increases effective primary crusher throughput by up to 15% by eliminating precrushed material.
Reinforced Structural Frame Design | Baza Teknike: Analiza e elementeve të fundme (FEA) optimized steel fabrication with highstress zone reinforcements | Përfitimi Operacional: Withstands continuous highcycle loading without frame fatigue or cracking common in highproduction environments | Ndikimi i ROI: Eliminates unplanned structural repairs, protecting asset lifespan over a 15+ year service period.
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi standard i industrisë | Thërrmimi ynë & Screening Solution Documented Performance | Avantazhi (% Përmirësimi) |
| : | : | : | : |
| Crusher Liner Wear Life (Shkëmb gërryes) | ~ 450,000 ton për grup (Cone Crusher Mn18) | ~520,000 tons per set (Proprietary Mn22 Alloy) | +15% Jetë më e gjatë |
| Screen Box Sideplate Vibration Fatigue Failure Mean Time Between Failure (MTBF) | ~8,000 operating hours before weld repair required| >14,000 operating hours before inspection advised| +75% Improved Durability |
| Konsumi i Energjisë (kWh per Ton Processed) Baseline for a 300tph Circuit| ~0.85 kWh/Ton Average| ~0.72 kWh/Ton Documented Average| 15% Kosto më e ulët e energjisë |
| Kostoja totale e pronësisë (TCO) gjatë 5 Years (Mirëmbajtja + Parts + Koha e ndërprerjes)| Indexed at 100% për krahasim| Estimated at 7882% of benchmark TCO| 18% te 22% Lower TCO |
5. SPECIFIKIMET TEKNIKE
Gama e Kapacitetit: Impiante stacionare nga 150 deri në fund 1,200 ton në orë (TPH). Trackmounted mobile units from 200 te 500 TPH.
Kërkesat për fuqi: Primary crushing units typically require 150400 kW drives. Full electric stationary plants may require a total connected load of 8002,500 kVA depending on scale.
Specifikimet e materialit: Fabrikuar nga çeliku strukturor S355JR; highwear components utilize HB500 abrasionresistant steel liners; crusher jaws/cones in premium manganese steel (Mn18Cr2/Mn22Cr2).
Dimensionet fizike (Example Mobile Unit): Transport length approx.16m; Operating length approx.19m; Max height approx.4m; Operating weight approx.45 tonnes.
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 25°C deri në +45°C; kushinetat e mbrojtura nga pluhuri (IP65+); capable of operating at altitudes up to 3,000 meters with engine deration.
6. Skenarët e APLIKIMIT
Projekti për zgjerimin e gurores së granitit
Challenge A major quarry needed to increase production by 40% without expanding their permitted footprint or adding a second processing shift.
Solution Implementation of a new tertiary crushing stage featuring a highspeed cone crusher paired with a tripledeck fine screen in closed circuit.
Results Achieved target throughput increase within existing footprint. The closedcircuit design reduced recirculating load by over half compared to the old layout while improving cubicity of the chip products.
Urban C&D Recycling Operation
Challenge Processing highly variable construction demolition waste led to frequent jamming in the primary impact crusher from uncrushable rebar matts and excessive fines clogging screens.
Solution Deployment of a heavyduty jaw crusher as primary stage for better tramp metal tolerance and an aggressive linear stroke screen ahead of secondary processing for fines removal.
Results Unplanned stoppages due to feeding issues decreased by approximately90%. The removal of fines early in the circuit significantly improved efficiency of downstream sorting equipment.
7 KONSIDERATA TREGTARE
Equipment pricing tiers are structured around capacity capability:
Niveli I (600 TPH): Customengineered stationary crushing and screening plants.
Optional features include advanced dust suppression systems automated metal detection/ ejection magnetic head pulleys extended conveyor systems
Service packages range from basic warranty support through comprehensive multiyear maintenance agreements including scheduled parts kits
Financing options are available including capital lease operating lease commercial loans tailored
8 FAQ
What level of ground preparation is required for installing this equipment?
Stationary plants require engineered concrete foundations Mobile track mounted units require stable compacted ground but minimal civil work enabling rapid redeployment
How does your equipment interface with our existing conveyors stackers?
Our engineering team provides detailed interface specifications for chute heights discharge trajectories belt widths ensuring compatibility
What is the typical lead time from order commissioning?
For standard mobile units lead time is typically weeks For large custom stationary plants detailed engineering procurement fabrication requires months
A ofroni garanci për performancën?
Yes we offer guaranteed minimum capacity based on agreed feed material specifications Guarantees are backed by pre purchase material testing circuit simulation
What operator training technical support do you provide?
We include comprehensive onsite training for operations maintenance crews along with digital manuals Access remote diagnostic support via data link standard
