Reliable crushing Low cost of maintenance
For cement plant owners today, reliability and durability of equipment are top of mind. Any technology investment needs to deliver on plant production goals, now and in the future.
This is particularly true for crushing equipment, which bears the brunt of constant impact and wear as it is knocked around by the very materials it is designed to process. Here, there are clear economic advantages of increasing wear parts' lifetime and making maintenance easier.
FLSmidth has recently introduced a crusher based on a strike-bar system, adding to its existing range of crushing equipment. The FLSmidth® Strike-Bar™¢ Crusher is built to help producers reduce the effect of wear and lower operating costs by combining more than 50 years of experience with impact crushers and the latest technologies. Some of these key technologies and features are discussed below or watch our video about the Strike-Bar Crusher in https://www.flsmidth.com to learn more.
Low total cost of ownership: Nothing is as hard on machinery as crushing raw materials day in and day out. A focus on longer wear lifetime and easy maintenance is therefore essential to minimize the Total Cost of Ownership for your crushing operations. FLSmidth® Strike-Bar™¢ Crusher has been designed specifically for the cement production process. It is built to reduce the effect of wear in a harsh operating environment and is designed to help your operations achieve their true potential.
High capacity: With a throughput capacity upto 2,600 tonnes per hour, reduction ratio upto 40:1, Strike-Bar™¢crusher can handle lump sizes larger than 2.0m and 4 tonnes in weight. The Strike-Bar Crusher will help you improve production processes, increase efficiency and lower operating costs.
Long wear life: We have focused on lengthening the wear life of the strike bars and quick and easy replacement of wear parts to cut potential downtime. Unique to Strike-Bar™¢ crusher are the interchangeable, segmented strike bars, designed to significantly maximise wear life. Interchanging between four different positions makes it possible to utilise up to 50 per cent of the total strike bar weight. With the wedge fastening system and hydraulically operated easy-to-open main housing, you can quickly rotate the strike bars.
'Five-minute' alignment: Another innovative development that reduces maintenance time is the unique hydraulic and spring positioning system. This impact crusher is the first crusher that prevents overload and eliminates stoppages. It consists of several hydraulic cylinders, each fitted with a hollow piston containing a spring system. The springs are carefully pre-tensioned to withstand impact during crushing operations.
Ensuring correct alignment of the gap between the rotors and breaker plates is crucial to achieving the desired size of crushed material. Whereas standard impact crushers can take up to several hours to align, this entire system can be easily aligned in just a few minutes thanks to the adjustable hydraulic cylinders, significantly reducing stoppage time.
Easy maintenance & installation
Ease of maintenance has been top of our design agenda. All exposed surfaces are lined with bolted-on wear resistance plates for extra durability and specially designed features. This ensures easy inspection and access to interior wear parts and quick maintenance.
The carefully designed housing consists of easily manageable welded sections. The four main pre-fabricated sections can be quickly put into place on-site to get you up and running without delay.
How it works
Raw material enters the crusher through the integrated Apron feeder. In the first part of the process, the material is crushed by impacting. Then, it is sheared and compressed between the strike bars, breaker plate and grinding plate. Together with the durable springs and adjustment systems, this eliminates many common stoppages and minimises equipment damage.
Multiple breaker & grinding plate
The crusher features a multiple breaker and grinding plate system in conjunction with a single rotor. Raw material is efficiently reduced to the required size - you can be sure that no oversized particles will leave the crusher.
Heavy-duty rotor and drive
Key to the crusher's performance is the robust rotor and drive system. As the heart of the crushing system, the strike bars are mounted on the rotor system. It is designed with three principles in mind;
- Easy replacement of the strike bars
- Maximum inertia in the top of the rotor
- Protection of the non-wear parts
The drive station is based on a proven FLSmidth gear solution û designed for a small footprint and easy maintenance. It includes safe-set coupling and a multi-joint shaft for easy alignment. The rotor design delivers maximum inertia for the crushing process and can be easily replaced with minimum operational downtime.
Impact & grinding plates
All breaker and grinding plates can be adjusted to compensate for wear and to fine-tune the output product by means of hydraulic cylinders. Together with the durable spring system, which helps prevent overload, this eliminates common stoppages and minimizes equipment damage. The breaker and grinding plates are easy to pull out for inspection and maintenance. As a safety measure, a slide rail system supports the plates inside the crusher even when the breaker and shaft grinding plates are disengaged.
Consistent and reliable feed to the raw mill is vital to achieve an efficient cement production process. It all starts with a reliable and durable crusher. A driving goal for FLSmidth is to help cement producers lower the total cost of ownership of their product equipment. When it comes to crushing equipment, FLSmidth product developers have focused intently on wear parts as a significant source of savings as well as simplifying maintenance throughout the crusher's lifetime. With the new FLSmidth® Strike-Bar Crusher™¢,, FLSmidth has taken a significant step towards achieving the goal.