Quarry Ballast Crushing Equipment Fabricator Datasheet

Përshkrimi i shkurtër:

1. PAINPOINT DRIVEN OPENING Are escalating operational costs and unpredictable downtime eroding your quarry’s profitability in ballast production? Sfidat e zakonshme përfshijnë: Veshja e Lartë & Shpenzimet e Mirëmbajtjes: Granit gërryes, bazalt, or limestone rapidly degrades crusher components, leading to frequent shutdowns and high parts replacement expenses. Gradim i paqëndrueshëm i produktit: Failure to meet strict railway or construction specifications…

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Detajet e produktit

Etiketat e produktit

1. HAPJE NGA PIKA E DIKIMIT

Are escalating operational costs and unpredictable downtime eroding your quarry's profitability in ballast production? Sfidat e zakonshme përfshijnë:
Veshja e Lartë & Shpenzimet e Mirëmbajtjes: Granit gërryes, bazalt, or limestone rapidly degrades crusher components, leading to frequent shutdowns and high parts replacement expenses.
Gradim i paqëndrueshëm i produktit: Failure to meet strict railway or construction specifications (p.sh., NË 13450) results in product rejection, cikle rishtypjeje, and wasted capacity.
Efikasitet i ulët i përgjithshëm i sistemit: Bottlenecks between crushing stages, manual adjustments for feed variations, and excessive fines generation directly reduce tonsperhour output.
Konsumi i tepërt i energjisë: Inefficient crushing chambers and drives consume disproportionate power per ton of final product, një kosto e madhe fikse.

Is your current crushing circuit a source of constant adjustment and cost, rather than a reliable, highyield asset? The solution lies in specifying equipment engineered explicitly for the sustained rigors of ballast production. Quarry Ballast Crushing Equipment Fabricator Datasheet

2. PËRMBLEDHJE E PRODUKTIT

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. Furnizimi i kontrolluar: 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. Shkarkimi efikas: Optimized discharge conveyor design minimizes recirculation load and chip damage to finished product.

Fusha e Aplikimit: Ideale për përpunim të vështirë, gërryes magmatik (granit, bazalt) and metamorphic rock for highspecification ballast. Kufizimet: Not designed for highly sticky, claybound materials or very soft sedimentary rock without significant circuit modification.

3. TIPARET THEMELORE

Rotor HeavyDuty & Sistemi konkav | Baza Teknike: Highinertia rotor design with interparticle crushing action | Përfitimi Operacional: Sustains higher throughput with lower tip speed, reducing wear energy cost by up to 15% krahasuar me dizajnet konvencionale | Ndikimi i ROI: Lower cost per ton through extended liner life and reduced specific energy consumption.

Rregullimi i hidrosetit CSS | Baza Teknike: Hydraulic main shaft positioning system | Përfitimi Operacional: Lejon operatorët të rregullojnë cilësimin e anës së mbyllur (CSS) në nën 60 seconds for gradation control or to clear a stall | Ndikimi i ROI: Minimizes noncrushing downtime by over 90% for setting changes compared to manual shim systems.

Sistemi i monitorimit të veshjes së astarit | Baza Teknike: Ultrasonic sensor array integrated into crusher frame | Përfitimi Operacional: Provides realtime data on mantle and concave wear profiles, enabling predictive liner changes | Ndikimi i ROI: Eliminates unexpected liner failure downtime and allows full utilization of liner material, reducing waste by an estimated 20%.

Lirimi i integruar i Tramp & Pastrimi | Baza Teknike: Automatic hydraulic overload protection with reversing clearing cycle | Përfitimi Operacional: Safely passes tramp steel and uncrushable material, then resumes operation without manual intervention | Ndikimi i ROI: Prevents catastrophic damage to crusher components and avoids hours of dangerous manual cavity clearing.

Dizajni i linjës modulare | Baza Teknike: Segmented concave sections with common bolt patterns | Përfitimi Operacional: Reduces liner changeout time by utilizing smaller, manageable components; safer for maintenance crews | Ndikimi i ROI: Shkurt kohën e planifikuar të mirëmbajtjes deri në 40%, rritja e orëve vjetore të disponueshme të prodhimit.

4. PËRPARËSITË KONKURRETARE

5. SPECIFIKIMET TEKNIKE

Gama e Kapacitetit: I konfigurueshëm nga 300 deri në fund 1,200 tonë metrikë në orë të produktit të përfunduar të çakëllit.
Kërkesat për fuqi: Makinë polic kryesor nga 200 kW deri në 500 kW; fuqia totale ndihmëse e impiantit varet nga konfigurimi.
Specifikimet e materialit: Constructed from highstrength alloy steel (kornizë); mantles and concaves available in multiple grades of manganese steel (Mn18Cr2 standard) or optional chromewhiteiron alloys for extreme abrasion.
Pranimi i madhësisë së furnizimit: Deri në 90% of crusher feed opening dimension (typically up to ~250mm).
Dimensionet fizike (Njësia primare tipike): Përafërsisht. Gjatësia: ~ 5 m; Gjerësia: ~ 3 m; Lartësia: ~ 3.5 m; Pesha: ~4570 tonnes.
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 20°C deri në +45°C; kushinetat e mbyllura me pluhur; në dispozicion pako opsionale për ngrohje/ftohje.

6. Skenarët e APLIKIMIT Quarry Ballast Crushing Equipment Fabricator Datasheet

Railway Ballast Production Plant – Scandinavia

Sfida: A granite quarry supplying national rail networks faced excessive wear costs and fines generation exceeding the strict <1% specification with their existing jawcone circuit.
Zgjidhje: Implementation of a primary gyratory crusher followed by a secondary cone crusher specifically configured for ballast production.
Rezultatet: Gjenerimi i gjobave u reduktua me mbi 50%, consistently meeting EN spec. Jeta e linjës u rrit me 30%, duke kontribuar në një dokumentuar 18% reduction in cost per ton of saleable ballast.

Integrated Aggregates & Ballast Quarry – North America

Sfida: Need for flexible production switching between road base aggregates (smaller sizes) and largesize railway ballast led to frequent circuit reconfiguration and lost shifts.
Zgjidhje: Installation of a multicylinder cone crusher with rapid Hydroset adjustment capabilities.
Rezultatet: Changeover between product specifications is now achieved in under 10 minutes via automated settings adjustment versus a previous 4hour mechanical shift change process.

7. KONSIDERATA TREGTARE

Nivelet e çmimeve: Equipment is offered in three capability tiers—Standard Duty (for consistent feed), Detyrë e rëndë (for highly abrasive rock), dhe Detyrë ekstreme (for maximum uptime requirements)—with corresponding capital investment levels.
Karakteristikat opsionale: Paketa të avancuara të automatizimit (ASRi), dust suppression integration kits specialized lubrication cooling systems remote monitoring telematics
Paketat e Shërbimit: Choose from Basic Warranty Extended Component Assurance Plans or Comprehensive Total Care Agreements covering parts labor scheduled inspections
Opsionet e financimit: 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 Cilat janë afatet e pagesës?
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