Pajisje dërrmuese të çakëllit të gurores Prodhuesi me etiketë private të lirë
Zgjidhje dërrmuese të çakëllit të shënjestruar të guroreve: Projektuar për vëllim, Efikasiteti, dhe me kosto më të ulët
1. HAPJE NGA PIKA E DIKIMIT: Kostoja e lartë e prodhimit joefikas të çakëllit
Prodhimi i qëndrueshëm, shkalla e specifikimit çakëll hekurudhor është një shtytës kryesor i përfitimit për guroret. Megjithatë, operational bottlenecks in your crushing circuit directly erode margins. A po i menaxhoni këto sfida të vazhdueshme??
Gjenerimi i gjobave të tepërta: Deri në 15% of processed aggregate can fall below the lower sieve size, creating unsellable waste that represents lost revenue and increased disposal costs.
Kubiteti & Elongation Failures: Suboptimal particle shape leads to ballast rejection, cikle rishtypjeje, and potential penalties from rail contractors for noncompliance with EN 13450, AREMA, or other standards.
Kohë joproduktive të paplanifikuara: Ndryshimet e shpeshta të rreshtit, component wear in abrasive granite or basalt applications, and unexpected breakdowns halt your entire primary circuit, kushton mijëra në orë në prodhim të humbur.
Konsumi i lartë i energjisë & Varësia e operatorit: Inefficient crushing action and manual adjustment systems lead to spiraling power costs and inconsistent output quality across shifts.
Grykat e ngushta logjistike: Can your current setup handle variable feed sizes from the primary crusher and maintain a steady, highvolume output of 4070mm aggregate without constant intervention?
The central question: Is your ballast crushing equipment a reliable profit center or a source of constant cost and compromise?
2. PËRMBLEDHJE E PRODUKTIT: HighCapacity Cone Crusher for Premium Ballast Production
Our dedicated quarry ballast crushing equipment is engineered as a tertiary or quaternary stage cone crusher designed specifically to transform secondary crushed feed (typically 100mm) into highyield, specificationcompliant railway ballast.
Rrjedha e punës operative:
1. Furnizimi i kontrolluar: Correctly sized feed from secondary crushing is introduced via a regulated feed hopper and conveyor.
2. Thyerja e ndërpartikulave: Material is compressed and crushed between the mantle and concave liners within a packed rockonrock chamber.
3. Kontrolli i saktë i madhësisë: The hydraulic adjustment of the crusher’s closedside setting (CSS) allows realtime tuning to exact product tolerances (p.sh., 4070mm).
4. Shkarkimi i vazhdueshëm: Crushed material exits the chamber, with oversize automatically recirculated, ensuring consistent final product gradation.
Fusha e Aplikimit & Kufizimet:
Fushëveprimi: Ideal for mediumtohard abrasive materials (granit, bazalt, gneiss) in fixedplant configurations producing 50500 TPH of ballast. Effective in both tertiary final shaping and quaternary recrush roles.
Kufizimet: Not designed as a primary crusher for runofquarry stone. Maximum feed size is dependent on model selection but typically does not exceed 150mm. Optimal performance requires prescreened feed to remove excessive fines.
3. TIPARET THEMELORE: Engineering for Superior Ballast Yield
Rregullimi i hidrosetit CSS | Baza Teknike: Pistoni hidraulik që mbështet boshtin kryesor | Përfitimi Operacional: Operators can adjust product size or perform clearing under load in under one minute from a remote location. | Ndikimi i ROI: Redukton kohën e ndërprerjes për rregullime deri në 80% krahasuar me sistemet manuale, rritja e disponueshmërisë së impiantit.
MultiZone Crushing Chamber | Baza Teknike: Optimized geometry with varying eccentric throw across crushing zones | Përfitimi Operacional: Promotes interparticle rockonrock crushing for superior cubicity while minimizing direct metaltometal wear on liners in abrasive conditions. | Ndikimi i ROI: Improves product yield within spec by 812% and extends liner life by an average of 25%.
Intelligent Automation System (IAS) | Baza Teknike: PLCcontrolled system monitoring power draw, presioni, and CSS | Përfitimi Operacional: Automatically regulates feed rate via VFD crusher drive to maintain optimal chamber loading and prevent ringbounce or cavitation. | Ndikimi i ROI: Ruan efikasitetin maksimal; të dhënat në terren tregojnë një konsistencë 610% reduction in energy consumption per ton produced.
HeavyDuty AntiSpin Device | Baza Teknike: Mechanical brake system on the main shaft | Përfitimi Operacional: Prevents uncrushed “spinouts” that cause uneven wear and product flakiness by stopping head spin during noload conditions. | Ndikimi i ROI: Ensures consistent particle shape over full liner life and reduces premature liner replacement costs.
Tramp Metal Relief System | Baza Teknike: Mbrojtje hidraulike nga mbingarkesa me rivendosje automatike | Përfitimi Operacional: Allows uncrushable material (p.sh., digger teeth) to pass without causing catastrophic damage or requiring manual clearing. | Përfitimi Operacional: Prevents costly component failures and associated production delays.
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi bazë i industrisë | Zgjidhja jonë për shtypjen e çakëllit të guroreve | Avantazhi i dokumentuar |
| : | : | : | : |
| Rendimenti i produktit (Within Spec) | 8285% typical yield on granite feed | Consistent yields of 9092% achieved through chamber design & control systems| +7% Përmirësimi |
| Liner Wear Life (Granit gërryes) ~50k tons per set average ~62k tons per set demonstrated +24% Përmirësimi |
| Energy Consumption per Ton kWh/ton varies widely with settings ~0.85 1.1 kWh/ton typical range 12% Reduktimi mesatar |
| CSS Adjustment Time Manual systems require >5 minuta <60 seconds via Hydroset system 89% Reduktimi i kohës |
| Koha mesatare ndërmjet dështimit (MTBF) Componentspecific; shpesh 3500 orë +75% Reliability Gain |
5. SPECIFIKIMET TEKNIKE
Kapaciteti i gamës së modelit: I konfigurueshëm nga 120 te 450 ton në orë produkt i përfunduar i çakëllit.
Kërkesat për fuqi: Makinë polic kryesor nga 132 kW në 315 kW (180hp 425hp), supplied by electric motor with softstart capability.
Specifikimet e materialit: Fabricated hightensile steel mainframe; manganese steel wearing parts (astar); optional ceramic composite liners for ultraabrasive applications.
Madhësia e furnizimit & Product Range: Maximum recommended feed size of 125mm; ClosedSide Setting (CSS) adjustable from 20mm to 60mm for precise control over final product sizing (p.sh., nominal 40/70mm).
Dimensionet fizike / Pesha: Approximate footprint range from 4m x 3m; weights from 18t to 35t depending on model.
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
Projekti Kombëtar i Hekurudhave për Furnizimin e Guritit të Hard Rock
Challenge A major granite quarry faced recurring penalties for excessive fines (<40mm) tejkaluar 15%, coupled with low throughput due to frequent manual adjustments on aging cone crushers.
Solution Implementation of our tertiarystage quarry ballast crushing equipment with automated control system was integrated into an existing threestage circuit.
Results Within one month of operation:
Gjenerimi i gjobave reduktohet më poshtë 9%.
Produkti u rrit me 22% due to stable automated operation.
Ballast rejection rate fell by over 95%, eliminating penalty clauses.
Aggregate Producer Diversifying into Rail Contracts
Challenge A producer needed new capability within an existing plant footprint but lacked space for extensive new infrastructure while ensuring strict compliance with AREMA 4A specifications.
Solution A compact configuration was supplied as a skidmounted unit complete with integral lubrication system and PLC controls requiring minimal civils work.
Results The modular solution was commissioned in under five days after delivery:
Achieved full specification compliance immediately upon startup through precise CSS calibration
Operates at design capacity of 280 TPH within the allocated footprint
Provided new market access without disrupting existing asphalt chip production
7 KONSIDERATA TREGTARE
Equipment pricing is structured around three core tiers based on capacity robustness:
Tier I Standard Duty Model (<200 TPH): For less abrasive materials moderate production targets provides essential features including Hydroset automation
Tier II HeavyDuty Model (~300 TPH): Our most common configuration includes all core features plus IAS automation extendedwear component package suitable for continuous hard rock operation
Tier III UltraDuty Model (>400 TPH): Includes heavyduty components ceramic composite liner options advanced predictive monitoring sensors designed for maximum availability in severeservice applications
Përmirësimet e veçorive opsionale:
Advanced remote monitoring telematics package
Dust suppression ring kit
Special alloy liners specific material profiles
Extended warranty coverage plans
Paketat e Mbështetjes së Shërbimit:
Planned maintenance agreements guaranteeing parts availability fixed annual cost
Onsite operator training commissioning services
Technical support hotline priority parts dispatch
Opsionet e financimit:
Capital purchase outright ownership
Operating lease structures preserving capital
Finance lease agreements leading ownership
8 FAQ
What primary crusher types are compatible?
Our equipment is designed as downstream stage It works effectively following any primary jaw or gyratory crusher provided secondary stage screening ensures correct (100mm tipike) shpërndarja e madhësisë së ushqimit
How quickly can we expect installation commissioning?
For standalone units installation typically requires five ten working days depending foundation readiness Commissioning operator training adds additional two three days We provide detailed site preparation documentation advance
What ongoing maintenance does this require?
Daily visual checks weekly lubrication system inspections are standard Major service intervals involving liner changes vary based material abrasiveness but typically occur every six nine months continuous operation Planned maintenance kits available simplify scheduling
Can this produce other products besides railway ballast?
Yes The precise hydraulic adjustment allows production various aggregate sizes e.g subbase roadstone chippings making versatile asset outside dedicated rail contracts simply changing CSS screen configurations
A ofroni garanci për performancën?
Yes We offer guaranteed throughput capacity product gradation curves based certified test reports using representative samples your site material prior purchase agreement
