Tongxin Machinery provides high-quality and cost-effective construction equipment, including concrete batching plants and stabilized soil mixing stations. Contact us for customized solutions.
science avenue, shangjie district, Zhengzhou city, henan province
1. Core Technical Specifications
1.1 Mixing Unit
- Model: JS3000 Twin-Shaft Forced Action Mixer
- Nominal Capacity: 3,000 liters (3 m³)
- Theoretical Peak Output: 180 m³/h
- Drive Motors: 2 × 75 kW
- Mixing Shaft Speed: 33–37 RPM
- Blade Tip Speed: 1.8–2.2 m/s
- Liner Material: High-Chromium Alloy Cast Iron, Hardness ≥ 58 HRC
1.2 Weighing & Batching System
Batching Item | Measurement Range | Static Accuracy | Dynamic Deviation | Sensor Type |
Aggregate Weighing | 0-4000 kg | ±0.5% FS | ±2% | Impact-Resistant Weighing Module |
Cement Batching | 0-1500 kg | ±0.2% FS | ±1% | Precision Weighing Sensor |
Mineral Admixture | 0-800 kg | ±0.2% FS | ±1% | Precision Weighing Sensor |
Water Batching System | 0-600 kg | ±0.5% FS | ±1% | Weighing & Flow Dual-Mode |
Additive Batching | 0-50 kg | ±0.1% FS | ±1% | Micro-Precision Weighing System |
1.3 Material Handling Systems
- Aggregate Storage: Total 100 m³ (4 × 25 m³ compartments)
- Horizontal Belt Conveyor: 1,000 mm wide, 1.6 m/s, 15 kW drive
- Inclined Belt Conveyor: 1,000 mm wide, 2.5 m/s, 45 kW drive, 18° incline
- Peak Conveying Capacity: 900 t/h
- Cement Silos: 4 × 100 t capacity (standard)
- Screw Conveyor: Ø325 mm × 9 m, 90 t/h, 18.5 kW motor
- Anti-Bridging System: Pneumatic vibrators, 0.6–0.8 MPa operating pressure
---
2. Frequently Asked Questions
Q1: What is the real-world production rate of the HZS180 plant? Why is it lower than the 180 m³/h specification?
A: Under typical operating conditions, the sustainable output ranges between 120–130 m³/h. The reduction from the theoretical maximum is due to:
1. Effective Mixer Discharge Volume: Approximately 90% of the nominal 3 m³ capacity.
2. Extended Cycle Time: Actual batching-mixing-discharge cycles average 70–75 seconds, about 20% longer than the ideal 60-second cycle.
3. Operational Delays: Time allocated for material handling, truck scheduling, and other logistical factors accounts for roughly 15% of total production time.
Q2: How is weighing accuracy maintained, and what long-term calibration practices are recommended?
A: Accuracy is ensured through a multi-layered approach:
- Hardware: High-resolution load cells (1:3,000), three-point suspended weigh hoppers, and fast-acting pneumatic valves (<0.3 sec response).
- Software: Automatic zero-tare before each batch, real-time drop compensation algorithms.
- Maintenance: Quarterly calibration checks, protection of sensors from moisture and vibration, and scheduled lubrication of mechanical parts.
Q3: What environmental protections are integrated into the plant?
A: The plant meets stringent environmental standards:
- Dust Control: Fully enclosed structure, dust leakage <0.5%; pulse-jet bag filters with >99.5% efficiency; dust emissions <20 mg/m³ (beats the 30 mg/m³ national limit).
- Noise Control: Acoustic enclosures on mixer (≤75 dB(A) at 1 m); overall site noise: ≤65 dB(A) day, ≤55 dB(A) night; vibration-damping foundations reduce transmission by 60%.
- Water Management: Sand/gravel separator handles 30–40 m³/h; process water recovery rate >85%; designed for zero liquid discharge.
Q4: What are the site requirements for installation?
A:
- Space: Minimum 50 m (L) × 20 m (W) level area.
- Foundation: Reinforced concrete, grade C30, minimum 500 mm thick, designed for ≥15 t/m² load.
- Embedded Parts: Level tolerance ≤3 mm, elevation tolerance ≤2 mm.
- Drainage: Minimum 1% slope, trenches ≥400 mm deep.
- Utilities: with 400 kVA transformer; water supply at 0.2–0.4 MPa, flow ≥10 m³/h; compressed air at 0.7–0.8 MPa, ≥1.2 m³/min flow.
Q5: What is the power consumption, and what energy-saving features are included?
A:
- Total Installed Power: 280 kW.
- Typical Operating Load: 180–220 kW, depending on production intensity.
- Energy-Saving Features: Smart stop/start of auxiliary equipment based on production schedules; high-efficiency IE3 class motors (≥93% efficiency).
Q6: What does the maintenance schedule involve?
A:
- Daily (per shift): Check mixer lubrication points (10), drain air system moisture, clean sensors.
- Weekly: Check/adjust conveyor belt tension, verify liner clearance (3–5 mm), inspect bolts.
- Monthly: Calibrate weighing system, check hydraulic oil quality, inspect electrical connections.
- Annually: Inspect/replace main shaft bearings, check wear on liners and blades, full control system diagnostic.
Q7: What is the expected service life and key component replacement intervals?
A:
- Overall Design Life: >15 years.
- Mixing Blades: 80,000–120,000 batches (depends on concrete abrasiveness).
- Liners: 60,000–100,000 batches.
- Main Shaft Bearings: ≥5 years or 10,000 operating hours.
- Conveyor Belts: 2–3 years (usage dependent).
- Core Electrical Components (PLC, etc.): ≥10 years.
Q8: How is consistent concrete quality achieved?
A: Through automated process control and data tracking:
- Process: Automatic compensation for raw material variations; mixing time controlled within ±1 second.
- Data: Every batch record stored permanently; automated quality reporting; trend analysis with early warnings for deviation.
Q9: What are the key advantages over comparable batching plants?
A:
1. Mixing Quality: Patented blade geometry ensures a mix uniformity coefficient of variation ≤0.75%.
2. Batching Precision: Three-stage weighing process improves accuracy by 30% vs. standard systems.
3. Energy Efficiency: Consumes 15–20% less power than industry average.
4. Smart Features: Remote monitoring, predictive maintenance alerts, and full digital integration.
5. Service Network: Local 24/7 technical support, OEM spare parts availability, and comprehensive training programs.
---
3. Support & Services
3.1 Documentation
- Complete engineering drawings (PDF & CAD)
- Electrical and hydraulic schematics
- Operation & maintenance video library
- OEM spare parts catalog
3.2 Technical Support
- Dedicated engineer consultation
- On-site installation supervision
- Hands-on operator training
- 24/7 emergency service hotline
3.3 Value-Added Services
- Remote Monitoring: Real-time plant performance dashboards.
- Preventive Maintenance Plans: Customized schedules based on your production.
- Upgrade Programs: Software updates and hardware retrofit options.
- Genuine Parts Supply: Guaranteed fast delivery of OEM components.
---
Contact Us for a Detailed Quote or Technical Consultation
[Your Company Contact Information]
