coal and stone crusher

1. PAIN-POINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate or coal processing margins? For plant managers and engineering contractors, the primary crushing stage is often the source of critical bottlenecks. Common challenges include:

• Excessive Wear & Maintenance Costs: Abrasive stone or inconsistent coal feedstock rapidly degrades standard manganese steel components, leading to frequent liner changes, labor costs, and parts inventory expenses.
• Unplanned Downtime for Blockages: Bridging and material packing in the crushing chamber halt production. Each hour of unscheduled downtime can cost thousands in lost throughput and idle labor.
• Inconsistent Product Gradation: Poorly controlled discharge settings result in off-spec product—oversized material that recirculates, increasing load and wear, or excessive fines that reduce saleable yield.
• High Energy Consumption per Ton: Inefficient crushing action and outdated drive systems lead to disproportionate power costs, directly impacting your cost-per-ton metric.
• Difficulty Handling Variable Feed: Fluctuations in feed size, hardness, or moisture content (especially in coal) cause throughput swings and potential choking, forcing operators to run below capacity as a safety margin.

Is your operation equipped to transform these challenges into controlled, predictable costs? The solution lies in selecting a coal and stone crusher engineered not just to process material, but to optimize total operational efficiency.

2. PRODUCT OVERVIEW

The Centurion Series Dual-Purpose Impact Crusher is a heavy-duty, rotor-based crushing system engineered for primary and secondary reduction of both quarried stone (limestone, granite, basalt) and run-of-mine coal. Its design prioritizes robustness for abrasive mineral processing and adaptability for friable material like coal.

Operational Workflow:

1. Feed & Pre-Screening: Incoming material is directed onto an integrated grizzly or pre-screen module, removing bypass fines to reduce crusher load and wear.
2. Controlled Impact Reduction: Material enters the solid-steel rotor assembly, where massive hammers (blow bars) accelerate feedstock against adjustable primary breaker plates. This impact fracture is the core reduction mechanism.
3. Adjustable Classification: Crushed material passes over an adjustable secondary apron/grate system. This determines the final product size; apertures are hydraulically adjustable under load for quick product changes.
4. Discharge & Conveying: Sized product discharges onto your downstream conveyor system. The high-inertia rotor ensures consistent material flow without pulsation.

Application Scope & Limitations:

• Ideal For: Medium-hard to hard abrasive stone (up to 250 MPa compressive strength), run-of-mine coal cleaning/sizing, recycled concrete/asphalt aggregate.
• Well-Suited For: Stationary plants or semi-mobile skid-mounted units requiring high reduction ratios (up to 20:1) in a single stage.
• Limitations: Not recommended for highly plastic, clay-contaminated materials without pre-processing, or for extremely hard, non-abrasive materials like pure quartzite where specialized compression crushers may be more appropriate.

3. CORE FEATURES

Hydraulic Adjustment System | Technical Basis: Integrated hydraulic cylinders acting on apron positions | Operational Benefit: Adjust final product size in minutes without stopping the crusher; clear blockages safely | ROI Impact: Reduces downtime for product changeovers by up to 80% versus manual shim systems

Mono-Body Rotor Design | Technical Basis: Single-piece, solid steel rotor casting with precision-machined hammer seats | Operational Benefit: Eliminates stress fractures; maintains dynamic balance at high inertia for consistent throughput | ROI Impact: Extends service life by 2-3x over segmented/welded rotors; reduces vibration-related bearing failures

Multi-Component Wear Package | Technical Basis: Interlocking wear plates in chromium carbide alloy & martensitic steel options | Operational Benefit: Site-specific material selection maximizes wear life; plates protect main body structure | ROI Impact: Lowers cost-per-ton for wear parts by 30-50%; eliminates need for full body welding repairs

Direct Drive Transmission | Technical Basis: Fluid coupling & V-belt drive eliminated via direct motor-to-rotor coupling via gearbox | Operational Benefit: Transmits 95%+ of motor power to crushing action; reduces footprint and maintenance points | ROI Impact: Improves energy efficiency by approximately 15%; reduces scheduled maintenance time

Active Tramp Protection | Technical Basis: Hydraulic release cylinders allow the rear frame to pivot under extreme overload (uncrushable) | Operational Benefit: Prevents catastrophic damage from tramp metal or digger teeth; automatically resets | ROI Impact: Avoids weeks of downtime and six-figure repair bills associated with major mechanical failures

4. COMPETITIVE ADVANTAGES

Performance Metric	Industry Standard	Centurion Series Solution	Advantage (% Improvement)
Availability (Uptime)	85-90% (scheduled & unscheduled stops)	> 94% documented field average	+5-10% more production time
Wear Life - Primary Liners (Abrasive Stone)	80k -120k MTON	>150k MTON typical	+25% to +90% longer life
Specific Energy Consumption	0.8 - 1.2 kWh/tonne	>0.65 - 0.75 kWh/tonne	~20% lower operating cost
Product Gradation Control (± target size)	±15% common	> ±8% with hydraulic adjustment	Nearly twice as consistent
Mean Time Between Major Overhauls	12-18 months	>24-36 months documented	Up to 100% longer service intervals

5. TECHNICAL SPECIFICATIONS

• Capacity Range: Models from 200 - 1,200 tonnes per hour (TPH), depending on feed material density and required reduction ratio.
• Power Requirements: Electric motor drives from 250 kW to 800 kW. Voltage tailored to site requirements (e.g., 415V / 3.3kV /6.6kV).
• Material Specifications: High-grade steel mainframe (S355J2). Wear component options include MN18CR2 martensitic steel for severe abrasion or ceramic composites for extreme applications.
• Physical Dimensions (Model C-650): Feed Opening: 1,320mm x 1,200mm; Machine Weight: ~48 tonnes; Footprint Length x Width: ~7.5m x ~3.2m.
• Environmental Operating Range: Designed for ambient temperatures from -20°C to +45°C with standard lubrication systems. Optional cold-weather packages (-40°C) and dust suppression sealing kits available.

6. APPLICATION SCENARIOS

#### Quarry Operation - Basalt Aggregate Production

Challenge A granite quarry faced excessive wear costs on their previous jaw-cone system when processing highly abrasive basalt feed (>200 MPa). Unscheduled liner changes caused over 300 hours of annual downtime.
Solution Installation of a Centurion Series impact crusher as the primary unit with chromium carbide primary wear plates.
Results Wear life on primary liners increased from approximately 90k tonnes to over 160k tonnes—a 78% improvement—reducing annual planned downtime by 60%. Consistent cubical product also improved downstream screening efficiency.

#### Coal Processing Plant - ROM Coal Sizing

Challenge A coal prep plant needed consistent (-50mm) product from highly variable run-of-mine feed containing clay bands and shale pockets causing frequent blockages in their existing roll crusher.
Solution Implementation of a skid-mounted Centurion Series crusher with active tramp protection and hydraulic apron adjustment enabled quick clearing of packed material without shutdowns.
Results Throughput stabilized at design capacity of 450 TPH despite variable feed conditions within two weeks after commissioning—a significant improvement over previous performance fluctuations between 300–400 TPH—while eliminating an average of eight blockage-related stoppages per month.

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is structured around capacity class:

• Standard Range Models (<500 TPH): Base configuration includes crusher drive motor starter panel basic walkways
• High-Capacity Models (>500 TPH): Includes integrated hydraulic power unit advanced PLC control system with remote monitoring ports extended access platforms

Optional Features:
Pre-screen module dust suppression ring automatic lubrication system special alloy wear packages remote diagnostic telemetry

Service Packages:
Choose from three tiers offering defined parts coverage labor rates inspection schedules:
Bronze – Basic warranty Silver – Extended wear coverage Gold – Full annual operating cost guarantee with performance clauses

Financing Options:
Capital purchase lease-to-own operating lease structures available typically structured over three five seven-year terms tailored cash flow requirements project financing can be arranged through our partners

8 FAQ

Q What type of foundation is required?
A Detailed foundation drawings are provided with purchase Our engineering team can review your site plans Static loads dynamic forces require a substantial mass concrete pad typically designed by your civil contractor

Q Can this machine handle wet sticky material like clay-bound coal?
A While capable impact crushers are less ideal than roll crushers for highly plastic materials We recommend a pre-screening scalping deck remove fines If significant clay is present discuss application details our engineers may suggest specific modifications feed chute design

Q How does the pricing compare traditional jaw cone setup?
A Initial capital outlay may be comparable lower than multi-stage jaw cone screen circuit The significant ROI comes from lower operating costs reduced energy consumption fewer wearable components less structural steel conveyors between stages leading lower total cost ownership over five-year period Field data shows payback period often under months based on tonnage processed

Q What is lead time delivery commissioning?
A Standard models ship within weeks order confirmation Custom configurations require weeks Factory-trained technicians provide supervised commissioning operator training ensure optimal startup typically requiring days on site

Q Are performance guarantees offered?
A Yes we provide written performance guarantees based on agreed feed material specifications covering minimum throughput maximum power consumption maximum wear rates These form part commercial contract