Under the trend of rapid development in global open-pit coal mines, metallurgical sand and gravel, and building materials mining industries, Heavy-duty Apron Feeder, as the core feeding equipment at the front end of the crushing station, has higher requirements for reliability, wear resistance and continuous operation capabilities.
And EXCT, as a equipment manufacturer specializing in the transportation and crushing screening systems of mining materials, with years of technical accumulation and overseas project experience, has stood out in the highly competitive mining markets such as Southeast Asia, the Middle East, Africa, and South America.
From the application of heavy mining to large-scale material conveying systems, each EXCT apron feeder can achieve uniform and stable feeding, wear resistance and impact resistance, extended service life and reduced maintenance requirements. At this point, many domestic and foreign mining owners and EPC contractors may have questions: Why can EXCT's Apron Feeder become a professional and internationally competitive plate feeder supplier? Now, let me explain this to you all.
With An Independently Developed System
Benchmarking Against International Brands
The heavy duty apron feeder is a product developed by our company based on the advantages of similar types of feeders from both domestic and international sources. It is specially designed for the three common problems faced by imported equipment, namely material leakage, low-temperature startup sluggishness, pan and chain wear speed. It is a dedicated apron feeder for open-pit mines.
Establishing The Production Capacity Calculation Model
Before the official production of the product, we use three technologies - 3D modeling, finite element stress analysis, and discrete element material simulation - to complete the force calculation of the entire machine. We conduct comprehensive strength checks on heavy-load components such as frame, pan, main shaft, and supporting wheels. This helps to prevent deformation and fracture of the equipment due to long-term heavy loading at the source. At the same time, we have mastered the self-developed formula for calculating the production capacity of plate feeding, which can precisely match the plate width and driving power of the equipment based on the material bulk density, particle size, and installation inclination angle, completely eliminating the problem of false production capacity indication.
Customized Design
EXCT supports one-on-one personalized customized solution design. The equipment structure can be adjusted according to the customer's material granularity, processing capacity, bin pressure, environmental temperature, installation inclination (0-16°), and semi-mobile crushing station's matching requirements. This enables us to provide customers with solutions that better meet their project needs. Our product specifications cover a full range of bandwidths such as 800/1600/2000/2400/2800, with production capacity ranging from 50 to 4000 t/h. They can be adapted to small-scale mineral processing lines and also meet the matching requirements of semi-mobile crushing station complete sets for open-pit mines with production capacity of tens of millions of tons.
With Intelligent Production Lines
Integrated Autonomous Processing Workshop
EXCT has established a complete heavy component processing workshop and possesses over 140 advanced manufacturing equipment from both domestic and international sources, including laser cutting, large lathes, gantry milling machines, shot blasting for rust removal, dust-free spraying, etc. All the core components are processed independently, with extremely low reliance on outsourced components. The entire production process is controllable in terms of quality; all the steel plates undergo shot blasting for deoxidation treatment uniformly, and the steel structure welding is completed before eliminating internal stress. Key weld seams are subject to 100% non-destructive testing to ensure the reliability of the component structure from all aspects.
Selection Standards For Export-Level Components
The frame uniformly uses Q355-ME steel, which is resistant to low temperatures and less prone to cracking in cold environments, suitable for high-latitude overseas mining areas.
The chain adopts the crawler chain (tank chain) used in bulldozers, combined with high-manganese alloy single circular arc wear-resistant pan.
The supporting wheels and rollers use 42CrMo forged parts with surface quenching process, and are matched with imported SKF heavy-duty self-aligning roller bearings.
The drive device selects international brands such as Siemens, ABB, SEW, and Flender for hard toothed planetary reducers, and is combined with explosion-proof frequency conversion motors.
Modular Split Design
The entire machine is divided into four independent modules: the machine head, the body, the machine tail, and the drive unit. The factory conducts pre-assembly inspection and then disassembles and packages them.
The dimensions of each module comply with the over-limit standards for maritime and land transportation, resulting in lower transportation costs.
After arriving at the customer's site, the assembly process is simple and does not require large lifting equipment, significantly shortening the installation period of the project.
Standardized Factory Inspection Process
Before each apron feeder leaves the factory, it must undergo a continuous no-load test run for no less than 2 hours. Simultaneously, the temperature rise, vibration amplitude, and sealing leakage of the equipment must be inspected.
Outstanding Equipment Performance
Heavy-Duty Design
A sturdy and durable steel support frame with anti-collision tracks, which can limit the deflection of the material tray and eliminate the permanent bending of the tray. Moreover, it can withstand all loads during startup and operation.
The lifting lugs are installed at the appropriate position of the frame, facilitating installation and future maintenance.
Can Be Installed Horizontally Or At An Angle
The EXCT apron feeder can be installed in both horizontal and inclined applications. They are suitable for various terrain structures. The high inclination angle also allows for the construction of compact devices and reduces the length of the apron feeder, thereby maintaining a lower investment cost.
Adjustable Throughput
It can be equipped with a frequency converter to change the speed of the variable-frequency motor, thereby altering the operating speed of the apron feeder pan. This enables the purpose of adjusting the processing capacity of the apron feeder to be achieved.
Economically Reliable
We can provide customized Apron Feeders of various sizes and parameters according to customer needs. The equipment is suitable for various working conditions and can complete heavy feeding and material transportation tasks. The entire machine adopts a sturdy and durable structural design. The core components have a longer wear-resistant cycle, significantly improving the overall service life of the machine. The daily maintenance workload is reduced, effectively reducing equipment downtime and enhancing overall production efficiency. This will help you achieve higher business profits.
Simple Operation And Easy Maintenance
The heavy-duty design offers high availability, ease of operation, low maintenance and operating costs, as well as higher profits.
Comprehensive Services At Home And Abroad
Project Delivery Support
We can provide a complete set of export materials, including complete equipment drawings, operation manuals, and factory inspection reports, etc. for export. Daily, we can offer remote video technical guidance. For large overseas projects, we can also dispatch engineers to the mining site to complete equipment debugging, providing comprehensive support for the usage needs of overseas customers.
Equipment Full-Cycle Service
- Pre-sale stage: Can conduct on-site inspections to assess the working conditions, accurately calculate production capacity, and provide customers with customized solutions.
- Production stage: Continuously update the customer on the production progress and complete the pre-assembly and verification of the complete machine before delivery.
- After-sales stage: Arrange professional technicians to provide free guidance on equipment installation and commissioning at the user's site, and offer free professional training to on-site staff to help improve equipment operation efficiency and reduce downtime risks.
- In case of equipment failure causing quality issues with the operating equipment, a clear response should be given within 1 hour upon receiving the notification. The team will arrive at the site within 24 hours. If necessary, the main designer and experts will be present to solve the problem on-site until the fault is resolved and production resumes, ensuring customer satisfaction.
- Product quality follows the "three guarantees policy", with a warranty period of one year.
Standardized Supply Of Wear-Prone Parts
The equipment is provided with a complete set of maintenance tools and short-term spare wear-prone parts upon delivery.
The wear-resistant parts such as pan, chain, and sprocket have a high degree of standardization, and can be quickly replenished both domestically and internationally, thereby reducing the long-term stocking pressure of spare parts for customers.
Combining the advantages of full independent R&D capabilities, standardized intelligent manufacturing processes, extreme working condition adaptability, global services, and comprehensive costs, the EXCT apron feeder has fully demonstrated its comprehensive hard power comparable to international equipment.
Whether it is the domestic mine import substitution renovation project or the new construction of open-pit mines and beneficiation lines overseas, the EXCT apron feeder is a high-quality choice that takes into account both long-term stable operation and overall cost control.
If you are the mining procurement manager or an EPC general contractor, and you need to calculate the Apron Feeder supporting scheme based on on-site materials, production capacity, bin pressure, environmental temperature, and installation inclination, please feel free to contact us at any time. We have many years of experience in providing services for overseas open-pit crushing and conveying complete sets of projects. We can offer precise capacity calculation, customized equipment optimization for specific working conditions, and one-stop delivery technical support for overseas projects. While ensuring the long-term stable operation of the equipment, we can effectively control the overall procurement and operation costs of your project, and provide you with more reliable and efficient apron feeder and bulk material conveying solutions.
