The company introduced foreign advanced technology to develop scrap crushing production line in line with China's national conditions. It uses the hammer method to break the scrap steel, in the crushing can be the surface of the scrap steel rust, paint and other dirt separation, and then under the action of the magnetic sorting system, will be mixed in the scrap steel non-metallic metals, plastics and rubber and other non-metallic waste separately piled. The bulk density of pure broken steel can reach 1.2t/m3, shorten the melting time, improve the output, and reduce the content of residual impurities in molten steel, which is the favored electric furnace steelmaking charge of steel mills, and brings good economic benefits to the smelting industry.

 

Principle and performance of crusher

 

Scrap crushing production line using the principle of hammering, in the high-speed, large torque motor drive, the host rotor. The hammer head on the top takes turns to hit the object to be broken into the chamber, through the space formed between the liner and the hammer head, the object to be torn into the specification of the broken object, and then under the action of the magnetic equipment, high quality broken steel with high purity can be obtained.

 

Processing material range (taking PSX-98104(6000 HP) crusher as an example) can process the following raw materials:

① Scrap the car (excluding engine transmission, fuel tank, tires, fire extinguisher explosive materials, etc.);
② Light materials with a density of not more than 1.2 tons/cubic meter after cutting or packing;
③ "white materials" such as household appliances, washing machines, refrigerators, etc.;
④ No. 2 heavy dissolved scrap (HMS2 scrap).

Unbreakable materials are:

(1) Explosive hazards
① Articles that have the possibility of causing explosion, fire, etc. Such as fuel tanks, LPG tanks, paint cans, aluminum powder, paint thinner tanks and chemical compounds; ② Sealed containers, cans, etc. Such as fuel tank, motorcycle oil tank, etc.;
(2) Others
① Steel wire rope with a thickness of 25 mm and a length of more than 6 meters.
② Low carbon steel shafts with a diameter of more than 60 mm and a length of more than 1 meter.
③ Steel plates with a thickness of more than 25 mm and a size of more than 300x300 mm.
④ Steel plate with thickness of more than 50 mm and size of more than 150x150 mm.
⑤ Section high more than 225 mm, or belly wall thickness more than 12mm, or length more than 6 meters.
⑥ Steel pipe with a section diameter of more than 225 mm, or a wall thickness of more than 12mm, or a length of more than 6 meters.
⑦ Steel ingot, billet and similar solid materials.

 

Serial parameter table

 

 

Model	Main motor power (kw)	Maximum rotating diameter of rotor (mm/nominal inch)	Feed track width (mm/nominal inch)	Output (t/h)
PSX-4060	150(110)	1072/40	1640/60	2-4
	300(220)			4-7
PSX-5060	600(450)	1270/50	1640/60	5-9
PSX-6070	750(560)	1526/60	1640/70	8-14
	1000(750)			12-8
PSX-6080	1000(750)	1510/60	2140/80	15-25
	1200(900)			18-28
	1500(1120)			25-35
PSX-6990	1500(1120)	1770/69	2440/90	28-40
	2000(1500)			35-45
PSX-80104	2000(1500)	2020/80	2740/104	40-50
	3000(2250)			50-80
	3500(2600)			60-90
PSX-88104	40003000)	2235/88	2740/104	70-100
	5000(3750)			85-125
PSX-98104	4000(3000)	2480/98	2740/104	80-120
	6000(4500)			120-180
	7000(5200)			160-200
PSX-124104	10000(8000)	3150/124	2740/104	300-400

 

The complete production line should be equipped with crawler conveyor, feed chute, feed roller, crusher, vibration conveyor, discharge belt conveyor, magnetic separation system, pile conveyor, non-magnetic material conveyor, hanging magnetic separator, hydraulic system, lubrication system, cooling system, water spraying system, dust removal system, piping system, electrical system, monitoring system, operating room and foundation set composition.

 

 

 

Crawler scale conveyor

 

With the ability to load ultra-wide and overweight materials, it can provide continuous feed for the crusher, which can be loaded with crushing waste and large objects to ensure smooth feeding and keep up with the processing capacity of the crusher.

The track plate is made of manganese steel plate and has convex claws on the plate, which has excellent wear resistance and anti-slip performance. The track chain and pulley group are configured with heavy load, which has good load-bearing capacity

 

 

Crusher main engine

 

The crushing machine is the core part of the whole crushing line. After the material from the feed rolling device enters the crusher, the tearing and shearing effect is produced under the rotating impact of the hammer head, and the required crushing steel can be obtained.
The roller presses the material under the action of dead weight and oil cylinder, so that the material can enter the crusher, and is equipped with anti-splash device. The roller drive motor is made of Swedish brand Heglon, which can be turned back and forth.
The main machine is located above the overall base, and there is a vibration isolation device below the base, which can absorb the vibration and impact of the crusher during operation and reduce the burden of the equipment foundation.
The rotor assembly is composed of a disk, a hammer head, a pin shaft, a pin protector, a spindle, a bearing assembly, etc. The bearing assembly is installed at both ends of the spindle, and the rotor is fixed on the base through the bearing assembly to obtain support. Using SKF bearings, the bearing assembly is equipped with a temperature sensor to monitor the temperature and prevent the bearing from being damaged by overheating.
The main machine is equipped with a cantilever hoist and a pull-out platform for easy replacement of wearing parts and internal daily inspection.
The side walls of the upper cover are welded with thick steel plates, and the lining plates with high wear resistance are installed on the inside. The bottom and top are equipped with grids, so that the entire crusher inner cavity is protected.

 

 

Magnetic separation

 

After crushing through the crusher, the material through the magnetic separation system through two stages of magnetic separation into magnetic and non-magnetic substances. The magnetic roller adopts the original imported Italian SGM products, which can recover more than 98% of iron metal.

 

 

The magnetic separation system is composed of magnetic drum, drive motor, adjusting arm, frame, hopper, discharge tank, etc.
The broken material is uniformly transported to the magnetic drum by the vibrating conveyor. Under the action of magnetism, the magnetic substance is adsorbed on the drum and rotates with the x drum to enter the magnetic material conveyor. The non-magnetic material falls directly from the hopper into the non-magnetic material conveyor.

 

 

 

Stowage conveyor

 

After passing through the two-stage magnetic separation system, the conveyor belt is driven by the electric roller to drive the magnetic material transferred from the two-stage magnetic separation system. Lift up for stacking transport; At the same time, under the action of the moving device, the conveyor can fan out in the range of 1-fixed Angle, so as to achieve a wide range of stacked broken steel.

 

 

Non-magnetic material conveyor

 

The non-magnetic material after secondary magnetic separation is put into storage through the conveyor of primary and secondary non-magnetic materials.

 

 

 

Environmental process - dust removal system

 

In order to meet the requirements of national environmental protection, it is equipped with a complete dust removal system to collect and treat the dust generated in the crushing process, and meet the emission standards required by the state. Through the dust removal system can also reduce waste paper, plastic and other thin impurities, improve the quality of crushing materials. Spare cyclone bag dry dust removal, cyclone Venturi water curtain dust removal, European dust removal and other options.

 

 

Computer control systems and surveillance systems

 

The computer control system monitors and controls the working status of the entire production line, monitors various faults and abnormal operations in real time, and effectively implements emergency protection measures.
The monitoring system is composed of several cameras and ITV monitors, which can transmit real-time working condition images to ITV monitors, or download mobile APP to realize remote monitoring on mobile phones, so as to keep track of the working conditions of on-site equipment at any time.

 

 

Platform composition

 

 

 

"Bokong technology intelligent equipment cloud platform". Sensors are set at the key nodes of the crushing line to collect the object parameters of field equipment, people, machines, materials, etc., to realize the digitization of the entire production line and provide active monitoring and maintenance services for the whole life cycle.
Scrap crushing production line, through the integrated application of the Internet of Things technology, the use of sensors to collect the status of each equipment to the Tianqidi intelligent equipment cloud platform, the use of cloud computing and big data technology real-time processing and analysis capabilities, intelligent analysis of equipment, real-time monitoring, to achieve the automatic collection of comprehensive conditions of the crushing line, intelligent analysis and active maintenance.
With the real-time monitoring and analysis function of the equipment status of the software platform, it can replace manual inspection, discover and eliminate faults in time, realize early intervention in maintenance, reduce the cost of traditional periodic maintenance and spare parts inventory, reduce unexpected shutdown time, improve equipment reliability, and improve the underlying production efficiency of the enterprise.
Bokong Technology intelligent equipment cloud platform, open up scrap crushing line industry 4.0 era!

 

 

Main function of system

 

1.automatic real-time device detection, instead of manual inspection, through IE browser anytime, anywhere to view device data.
2.a variety of alarms timely convey reminders. Support SMS, wechat, email alarm information push function.
3. Diagnosis of expert knowledge base. The system automatically detects the source of the fault, reports the fault, and provides maintenance guidance.
4. Periodic reports. Provide regular equipment status analysis report.
5. Hierarchical user rights. Provides multi-level user management, and provides different levels of data reports according to the user management level.

 

 

 

After-sales license commitment

 

① Our company implements tracking service for products, and carries out pre-sale, sale and after-sales service for customers.
Pre-sale: equipment layout, equipment foundation guidance;
In sale: equipment production, delivery, installation and commissioning technical services;
After-sales service: customers daily maintenance, safety production and other services to ensure the normal operation of equipment.
② The equipment warranty period is 18 months of arrival or 12 months of acceptance (whichever comes first), and the user's fault feedback within the warranty period is replied within 4 hours, Hebei Province within 8 hours to the scene, and outside the province within 24 hours to the scene.
③ Equipment daily loss parts to provide customers with original parts and processing drawings, convenient for customers to choose.