Does the quartz sand impact sand making machine have poor particle shape and
high return material? Shanlu Heavy Industry customizes solutions to improve
production and quality
In the quartz sand making process, the impact sand making machine is the core
equipment that determines the quality and production capacity of the finished
sand particles, especially suitable for the production of high-end products such
as photovoltaic glass and petroleum fracturing sand (requiring a needle like
content of ≤ 8%, a return rate of ≤ 15%, and a sand making efficiency of ≥
150t/h). Currently, many quartz sand enterprises are facing problems such as
traditional sand making machines not meeting particle size standards, high
return rates, and fast wear of vulnerable parts, resulting in low product added
value and a sharp increase in operation and maintenance costs. As a national
high-tech enterprise, Shanlu Heavy Industry has been deeply involved in the
research and production of quartz sand full process equipment for more than 10
years. It has more than 100000 square meters of standardized factory buildings
and dozens of core technology patents. It can provide one-stop services from
equipment customization, installation and commissioning to after-sales operation
and maintenance. Its customized solution for impact sand making machines has
successfully helped enterprises in Jiangxi, Shandong and other places achieve
high yield and quality improvement.
1、 The three core shortcomings of traditional impact sand making machines
Based on the research data of more than 100 production lines conducted by the
technical team of Shanlu Heavy Industry, traditional impact sand making machines
are difficult to adapt to the production needs of large quartz sand. The core
shortcomings are concentrated in three points: firstly, the universal structure
of the crushing chamber and impeller is not suitable for the high hardness
characteristics of quartz sand at Mohs 7, resulting in poor particle shape
(needle like content exceeding 15%); Secondly, parameter regulation is rigid and
cannot be dynamically adjusted based on raw material particle size and hardness,
resulting in a return rate generally exceeding 30%; Thirdly, the wear resistance
of vulnerable parts is insufficient, and the service life of impellers and
impact plates is less than 800 hours, which hinders production capacity due to
frequent replacement. These shortcomings directly constrain the output and
market competitiveness of high-end quartz sand products in enterprises.
2、 Shanlu Heavy Industry Customized Solution: Precise Breakthrough in Three
Dimensions
Shanlu Heavy Industry abandons the industry's standardized equipment design
concept and relies on its strong research and development capabilities and rich
project experience to create exclusive optimization solutions for the sand
making characteristics of quartz sand. Each optimization is tailored to the
actual production needs of the enterprise and differs from traditional extensive
transformation.
1. Customized crushing structure: adapted to the characteristics of quartz
sand, optimized particle shape to reduce material return
The traditional sand making machine has a fixed crushing chamber angle and a
single impeller structure, which cannot achieve precise crushing. Shanlu Heavy
Industry customized optimization: adopting a patented "multi cavity crushing
structure", adjusting the angle of the counterattack plate (20 ° -25 °)
according to the particle size requirements of the enterprise's finished
products (such as 4-120 mesh plate sand, 0-3mm fracturing sand), and combining
it with an arc-shaped guide liner to enhance the "stone hitting" crushing
effect. The needle like content can be reduced to below 8%; Optimize the layout
of impeller blades, adopt high chromium alloy integrated molding impeller,
increase the blade thickness to 25mm, calibrate with a dynamic balance
instrument (deviation ≤ 0.5g · m), stabilize the material ejection trajectory,
and control the return rate within 15%, solving the problem of excessive return
of traditional equipment.
2. Intelligent parameter adaptation: dynamic regulation, balancing production
capacity and quality
Parameter rigidity is the key to the imbalance between production capacity
and quality. Shanlu Heavy Industry has equipped the equipment with an
intelligent frequency conversion control system, which can dynamically adjust
the operating parameters according to the hardness of quartz sand and feed
particle size. When processing high hardness quartz sand, the impeller speed is
accurately controlled to 2500-2800r/min to ensure crushing strength; When the
feed particle size fluctuates, the system automatically adapts the feeding speed
(maintaining at 85% -95% of the rated value) to avoid overload accumulation. At
the same time, it is equipped with an online particle size monitoring device
that provides real-time feedback on finished product particle shape data,
supports remote parameter fine-tuning, and does not require manual on-site
monitoring, significantly reducing operation and maintenance costs. This
intelligent adaptation technology is one of the core advantages of Shanlu Heavy
Industry's years of technological accumulation.
3. Upgrade of wear-resistant system: extend service life, reduce operation
and maintenance losses
The high abrasion of quartz sand can easily lead to rapid wear of vulnerable
parts, which is the main pain point for enterprise operation and maintenance.
Shanlu Heavy Industry has upgraded its wear-resistant system with targeted
measures: key components such as impellers and impact plates are made of high
chromium alloy composite materials (hardness HRC ≥ 62), with a tungsten carbide
wear-resistant layer welded on the surface. The service life has been extended
to over 2000 hours, which is three times that of traditional materials; The
equipment sealing structure adopts a dual design of "labyrinth seal+negative
pressure adsorption" to prevent dust from entering the bearings. Combined with
an automatic lubrication system, the bearing temperature is stable below 65 ℃,
and the failure shutdown rate is reduced by 70%. Relying on standardized
production bases, Shanlu Heavy Industry can quickly supply customized
wear-resistant spare parts to ensure the continuous operation of production
lines.
Case evidence: The core value of implementing the plan
A float glass sand enterprise in Jiangxi with an annual output of 300000 tons
had a qualified product rate of only 82% due to the poor particle shape and high
return rate of traditional sand making machines. After adopting the customized
impact sand making machine solution from Shanlu Heavy Industry, the needle like
content of the finished product was reduced to 7%, the return rate was
controlled at 12%, the sand making efficiency was improved to 180t/h, and the
product fully met the sand standards for float glass. The added value of the
product increased by 30%, and the annual profit added exceeded one million yuan.
The smooth production of this project fully demonstrates the pertinence and
implementation of Shanlu Heavy Industry's plan.
Shanlu Heavy Industry has always focused on the production needs of quartz
sand enterprises, covering customized equipment for the entire process of sand
making, purification, environmental protection, and packaging. Its products have
passed ISO9001 quality system certification and are exported to multiple
countries and regions in Southeast Asia, Africa, and other areas. If your
production line is facing problems such as poor particle shape, excessive
material return, and easy wear of impact sand making machines, or if you have a
need for customized or upgraded sand making equipment, please feel free to
contact Manager Zhang at 13583776655 or WeChat. Shanlu Heavy Industry's
professional technical team will provide one-on-one communication and tailor
efficient solutions to meet your production needs, helping enterprises seize the
high-end quartz sand market.