All that time it took to design and build postponed your ability to generate income. What if we told you we've got a library of pre-engineered plants ready to build, rapidly install and produce profit?
Superior replacement crusher parts are taken from the same warehouse used for our manufacturing operations. That means you get an equal part, with equal quality, thats designed exactly for your machine.
Our ancestors must be looking down at us in envy. Before telescoping radial stackers like the TeleStacker Conveyor they attempted to overcome segregation with loaders, only to reinvest any profits right back into those inefficient trucks.Some of them understood the value of layered stockpiling and used dozers to push material. Unfortunately, running over the product compacted and crushed their precious sand. The smartest quarrymen and women of the past used conveyors, but without variable heights or radial travel, the material was segregated before it even left the belt.Today, were blessed with technology to help build partially and fully desegregated stockpiles. These modern radial stacking conveyors extend and retract, move radially and have variable discharge heights. These are the basic features of a telescoping stacker. Established in 1997, the TeleStacker Conveyor is pound-for-pound the strongest, safest and most productive telescopic stacker on the planet. Every square inch of steel is designed to carry more load, provide more stability, and move material at the lowest cost per ton.
While some programs result in flat top stockpiles, our exclusive zoning method instructs the radial telescopic conveyor to stockpile more in the back. This creates a trapezoidal-shaped, higher volume stockpile.
There are many factors that contribute to segregation within a stockpile constructed by a standard conveyor.Fine particles settle to the bottom of belts, coarse material discharges faster, free-falling sand rubs and erodes, and wind affects the trajectory of particles differently.
Inconsistent gradation makes it nearly impossible to produce an acceptable asphalt or concrete product. Roads constructed with segregated aggregate have poor structural integrity and shorter life expectancy than those made from properly desegregated products.
Building stockpiles in thin layers with variable height stackers is most effective for minimizing segregation. Usually aided by automation, the stackers variable height, extension and radial position is essential in making layered piles that overcome segregation.
Geneva Rocks Ed Clayson is an industry veteran and has trusted Superior conveyors and components for the majority of his career. Get an inside look at Geneva Rocks production and learn about the conveying systems they use, which includes a mighty new TeleStacker Conveyor.
We always have been and always will be a privately-owned company. That means we can add more employees to our customer service team without Wall Street breathing down our neck. Isnt that the way it should be?
All roads, you might say, lead to the Vertical Shaft Impactor (VSI) because these crushers make it possible to create roadways and just about everything else. Francis E. Agnew of California patented one of the first Vertical Shaft Impactors in 1927. His configuration stacked three VSIs atop each other to produce sand, thus starting the VSI evolution.
Today, VSI crushers and the folks who rely on them have produced many configurations to include everything from the addition of cascading material into the crushing chamber, to air swept separation of lighter product. One version suspends the shaft from above like a sugar centrifuge. Its also one of the most feature-patented crushers, so some of the things mentioned here might be unique to a single manufacturer. VSIs apply a large amount of energy to crush material and thats why its one of the most versatile crusher configurations today.
When it comes to producing materials such as aggregate for road making, VSI crushers use a high-speed rotor and anvils for impact crushing rather than compression force for the energy needed for size reduction. In a VSI, material is accelerated by centrifugal force by a rotor against the outer anvil ring, it then fractures and breaks along natural faults throughout the rock or minerals. The product is generally of a consistent cubical shape, making it excellent for modern Superpave highway asphalt applications. The rotor speed (feet per minute) controls final particle size.
The VSIs high cubical fracture percentage maximizes first-pass product yield and produces tighter particle size distribution. It has a high-throughput capacity ideal for beneficiation (elimination of soft material). Properly configured the VSI accepts highly abrasive materials. It has simple operation and maintenance. You can quickly change product size by changing rotor speed or cascade ratio. Some models have reversible wear parts to reduce downtime. The VSI typically has low operating costs even in high-moisture applications because of reduced energy costs and low wear cost per ton.
There are some feed size limitations with a VSI because of the small feed area available in the center of the rotor. Tramp material in the feed such as gloves, tools, etc. can cause problems with imbalance. The high RPM and HP require careful balance maintenance such as replacing shoes on both sides of the rotor at the same time. High wear part cost may be a problem for some hard abrasive materials, but the VSI may still be the best option.
Major limestone applications are for Superpave asphalt aggregates, road base, gravel, sand and cement. Industrial uses include: corundum, corundite, ferro silicon, glass, refractories, silicon carbide, tungsten carbide and zeolite. Mining applications include: bauxite, burnt magnesite, iron ore, non-ferrous metal ore, perlite and trona sulfate. VSIs are excellent for everything from abrasive materials to waste and recycling applications.
Feed size and characteristics will affect the application of a VSI. The feed size is limited by the opening in the center of the rotor. Normally less than 5-inch material is desired, but very large VSIs can handle up to 12-inch feed. Another feature that will affect application is moisture, which can make the feed sticky. Required production capacity is the final limiting criteria. Large primary horizontal shaft impactors can output up to 1600 TPH and more. 1000 TPH is about the maximum for a VSI because of the limiting motor size and the rising G-force of a high-speed rotor, which is calculated by multiplying the radius times the square of the RPM.
Shoe configurations are many: rock on rock, groups of rollers, special tip wear parts and many others. The metallurgy of the shoes is also highly varied. Rotors can have three to six shoes. The number of shoes is typically governed by the diameter of the rotor. The larger the diameter rotor, the more openings are possible. Computational Fluid Dynamics (CFD) mathematical models are utilized to simulate the flow and collision forces to reveal solutions for lower wear cost, consistent final product, and higher energy efficiency.
The material to be crushed is fed into the center of an open or closed rotor. The rotor rotates at high rpm, accelerating the feed and throwing it with high energy into the crushing chamber. When the material hits the anvil ring assembly, it shatters, and then the cubical shaped product falls through the opening between the rotor and the anvil and down to the conveyor below.
The typical VSI is fed, from above, into the center of its rotor. The material is then flung across an open void to the crushing chamber. It then impacts the outer anvil ring. This crushing action imparts very high energy to the material and is very effective on most types of material. It gives a very uniform and consistent grade of product.
In cascade feeding, material bypasses the rotor and enters the crushing chamber from above. Its called cascade feeding because as material fills up a large feed bowl, with an outer diameter larger than the outer diameter of the rotor, it spills over the side and falls into the crushing chamber from above, bypassing the rotor. The effect of increasing feed through cascade is similar to slowing the rotor. Cascade feeding in amounts up to 10 percent may have no effect on particle size distribution or quality. The product gradation curve and product shape will change, if an increased amount of cascade feeding is used.
The VSI features multiple rotor/anvil configurations for various applications. From open or enclosed rotors to the tubular rotor, each machine is configured for their unique application. In many cases the rotor table, rotor assemblies, anvil ring or rock shelf are interchangeable, allowing maximum application flexibility.
The open top metal rotor is good for large feed or medium to very hard material, but it will work best for softer materials. It can handle medium abrasive, dry or wet, but not sticky materials. High reduction ratios are common, which are excellent for sand and gravel production in closed loop systems. Shoe shape can change the production size range. A straight shoe face design produces finer product, and a curved shoe face design produces coarser material.
The tubular rotor creates higher tip-speeds, which increases first pass yield with tighter particle size distribution and also reduces the recirculation loads. One unique feature is that the rotor rotation is reversible, allowing wear on both sides of the tube. Rotating the tube itself one-quarter turn also doubles the wear.
Any time the material or rock is used as an impact wear surface the term autogenous is used. Putting a top on the rotor table and shoes allows autogenous use. During operation of the VSI, a bed of material can be designed to build up inside the rotor against each of the shoe wall segments. The bed, which is made up of material that has been fed to the rotor, extends to a wear tip. The bed protects the shoe wall segment from wear.
Concerning the rock shelf anvil, it forms a near vertical wall of material upon which the accelerated material impacts. Rock-on-rock crushing reduces maintenance but can require up to 30 percent of material recirculation before meeting size requirements. Also, the rock shelf anvil absorbs energy that could otherwise be used for breaking, which may reduce efficiency. More RPM may be needed to achieve the same result as a solid metal anvil.
Good for medium abrasive materials, rock-on-rock configurations of either or both rotor and anvil may produce consistent material with low-wear cost and can handle wet but not sticky conditions. Reduction ratios from 2:1 to 5:1 can be expected. Its widely used for quarried materials, such as sand and gravel.
The VSI is one of the most versatile crushers available on the market today. Even with some limitations, like feed size and output capacity, VSI features have been and continue to be developed to maximize first-pass yields and lower operating costs. If you test your process on full-scale equipment before choosing your VSI, you wont be disappointed.
Stedman Machine Company works closely with its customers to determine the best, most cost-effective, efficient size reduction method and equipment for specific applications. Stedmans line of equipment includes: Cage Mills, Grand Slam and Mega Slam Horizontal Shaft Impactors, V-Slam Vertical Shaft Impactors, Hammer Mills, Aurora Lump Breakers, Micro-Max and Vertical Roller Mill Air Swept Fine Grinders. Stedman operates a complete testing and toll processing facility staffed by experienced technicians with full-scale equipment, allowing customers to witness accurate crushing test results, predicted output capacities and processing data. Support services include system design and 24-hour parts and service.
The VSI is amid the most multipurpose crushers obtainable on the marketplace nowadays. Even with several confines, such as output capacity and feed size, VSI aspects have been plus remain to be developed to exploit first-pass yields and lower operational charges. If you test the procedure on full-scale apparatus prior selecting the VSI, you will not be disillusioned.
Feed material drops via the feed tube to the enclosed propeller or impeller table which, via centrifugal power, tosses the material against fixed anvils comprised of complex metal alloys. Whenever the rock hits the anvils, it smashes alongside natural stress lines, forming an even, cubical product. That crushing method is inexpensive and simple to operate.
Key limestone uses are for road base, gravel, cement, sand and Superpave asphalt aggregates. Industrial applications comprise: corundite, refractories, ferro silicon, corundum, glass, tungsten carbide, zeolite and silicon carbide. Applications for vsi crusher in mining embrace: iron ore, burnt magnesite, perlite, bauxite, trona, non-ferrous metal ore and sulfate. VSIs are apt for everything from recycling and waste applications to the abrasive materials.
Whenever it comes to creating materials like aggregate for making roads, VSI crushers employ an ultra-fast rotor plus anvils for impact smashing instead of compression power for the energy wanted for size lessening. Inside a VSI, material is speeded by centrifugal force via a propeller against the exterior anvil ring; it at that point breaks and fractures alongside natural faults right through the minerals or rock. The product is usually of a regular cubical figure, making it outstanding for contemporary Superpave highway asphalt uses. The propeller speed (feet per minute) determines ultimate particle dimension.
The VSIs high cubical breakage ratio maximizes initial-pass product yield plus generates tighter element size dissemination. It has a high-output capacity perfect for beneficiation (removal of lax material). Correctly set-up the VSI accepts extremely coarse materials. It has modest maintenance and operation. You can hastily change product size by varying cascade ratio and rotor speed. Several models have adjustable wear parts to decrease interruption. The VSI characteristically has low operational overheads even in high-moisture employment owing to abridged energy expenses plus low wear price per ton.
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RD group proudly presents 350 tph crusher plant installed and operating in Jalana and Solapur. The plant as commissioned 2 months back, and have been rigorously running ever since. Delivering 350 tph aggregate 0-40mm size and around 260 tph 0-22mm size. The plant has a combination of 44x36 Jaw crushers along with 2 parallel cones of 150tph and 250 tph synchronized to feed the VSI of 400tph. The plant has 22 x 6 screens and is fitted with a Washing system with hydro-cyclone to fetch Plaster and concrete sand. The plant works at 1250KVA DG set and has been satisfying and enhancing customer satisfaction every day.
Comparing the profit the machine can give, the owner never feels cost a high for the machine. Our Engineers have done careful techno-commercial study to make the machine an easy buy option compared to other sand makers.
Our happy to help service is active 24 x 7 of the week and gives us a high rating on customer service. We have developed our own better quality spares for replacement while maintenance. The wear out parts are replaced at proper timing by proper servicing. Hailstone is offering good quality Spares at low cost for their customers for proper maintenance.
Always use Hailstone standard spare and wear parts for best fit and longevity of the machine. Splicing any non-standard spare or wear part on the machine put them at risk. Hailstone has a complete offering, for both standard and engineered-to-order parts, ensuring you have the availability and support required. We provide flexible options to secure parts on a one-time basis, as a turn-key service, or anywhere in between.
Our team is always a call away. We have 24x7 operational happy to serve team of service engineers in case of any customer need related to machine. Any problem for running the machine is immediately attended and rectified with utmost responsibility and care.
Proper maintenance is the key for smooth and efficient running of the machine. Hailstone offers end to end services inclusive of inspection and diagnostics, repairing, shut down solutions and planning and emergency services.