Crusher Hammer for Coal-Fired Power Plants| SUPER Manufacture

Top Crusher Hammer Heads Manufacturer in China for Coal-Fired Power Plants

SUPER is one of global famous manufacturers and suppliers of coal-fired power plant crusher hammer heads in China. The crusher hammer heads produced by SUPER are perfectly suitable for your crusher models. SUPER can also produce crusher hammers according to your drawings or samples. The hammer heads for coal power plant crushers manufactured by SUPER feature excellent wear resistance, high hardness, excellent toughness, and outstanding impact resistance. The high-performance crusher hammer heads manufactured by SUPER are competitively priced. Whether in China or global coal-fired power plants, SUPER crusher hammer heads perform very well and have achieved higher reputations.

High Chrome Crusher Hammer Heads for Coal Crushers

Heavy-Duty Crusher Hammer Heads for Coal Crushing Equipment

Ring-Type Crusher Hammer Heads for Hammer Mills

Replaceable Crusher Hammer Heads for Power Plant Applications

Twin-Shank Crusher Hammer Heads for Coal Crusher Systems

Long-Life Crusher Hammer Heads for Thermal Power Plants

Wear-Resistant Crusher Hammer Blocks for Power Generation Industry

High Impact Crusher Hammer Heads for Coal Pulverizing Systems

Workers at the SUPER factory are operating the casting production line

What Makes a Good Power Plant Coal Crusher?

A good coal power plant crusher hammer has several outstanding characteristics, such as hardness, wear resistance, and impact resistance. It must be matched to the coal crusher and achieve a balance between wear resistance, toughness, impact resistance, hardness, and dimensions. The material of the crusher hammer head should be determined based on the coal’s moisture content, coal gangue content, crushing loads, and other factors. So, when considering all these factors, it should be able to match your crusher perfectly. It can crush the required coal particles with higher working efficiency and also maintain better stability during long-term crushing, helping you reduce the loss caused by downtime, improve your working efficiency, and minimize your working costs.

SUPER Crusher Hammer Head Lost Foam Patterns in Foundry

What Is a Coal Crusher Hammer Head?

The coal crusher hammer is a key part of the crusher. It is installed inside the crusher chamber. The crusher’s rotor’s high-speed rotation drives the crusher’s high-speed rotation and movement of the hammer head. Then it strikes the original coals fed into the crusher chamber, reducing them to the required sizes, and then discharges them from the crusher. The crusher hammer head has a significant influence on the crusher capacity, particle control, and the crusher’s working efficiency.

Workers at SUPER Foundry Making Lost Foam Patterns for Crusher Hammer Heads

Where Crusher Hammers Are Used in a Coal-Fired Power Plants

Different coal-fired power plants have different working procedures. However, coal crushers are usually used after screening to crush large-sized coal. So each coal crusher’s hammer is installed inside the crusher chamber, and it crushes the screened, large-sized coal into smaller sizes, suitable for conveying, storage, and milling. Different coal-fired power plants use different crushers. SUPER can manufacture crusher hammer heads for different coal crushers, like Hammer Crusher, Jaw Crusher, Cone Crusher, Gyratory Crusher, Impact Crusher, Hammer Mill, Roll Crusher, VSI Crusher, Mobile Crusher, and so on. We produce crusher hammers based on your crusher models and drawings. Feel free to contact us and share your crusher’s information; we will discuss whether we can provide you with the right crusher hammer. But mostly, we can provide hammers for almost all crusher models.

SUPER Foundry Workers Making Wax Patterns for Crusher Hammer Heads

Compatible Models and OEM Replacement Parts

You can rest assured that the hammer heads we manufacture are fully compatible. We can produce almost all the global brand crushers’ hammer heads. If you can provide drawings or dimensions, it will be much easier for us. If you don’t have any drawings or dimension information, we have a set of measurement methods. We can guide you in measuring the critical areas, and then you can provide us with the measurement photos. You can also send the hammer sample to us. In that case, we can not only obtain accurate dimensions but also test the material properties and characteristics. This will allow us to build on this foundation to make improvements and produce hammer heads with better performance and more precise dimensions.

SUPER foundry wax patterns for wear-resistant crusher hammer heads

Coal Characteristics That Affect Hammer Head Wear

The working efficiency of a coal crusher hammer head is not only influenced by the hammer’s material but also by the moisture content of the coal, coal gangue, and hard material content, the feeding material’s particle size, ash, other objects, and the stability of feed rates. Together, they determine the crusher’s crushing efficiency.

Below, we will provide a detailed explanation of how these factors affect the crushing efficiency of the hammer head and the production capacity of the crusher:

Double-Lug Crusher Hammer Heads for Coal Crushers

Heavy-Duty Fork-Type Crusher Hammer Heads

Single-Lug Crusher Hammer Heads with High Impact Resistance

Twin Hole Crusher Hammer Heads for Hammer Mills

Round Shank Crusher Hammer Heads for Coal Crushing

Horizontal Pin Crusher Hammer Heads for Power Plants

Compact Crusher Hammer Heads for Industrial Crushers

High Impact Tube-Type Crusher Hammer Heads

Moisture

Moisture itself cannot influence crusher hammers, but it influences the stickiness between coals and hammer heads. It will cause the coal to adhere to the surface of the crusher hammers, leading to accelerated localized wear on the hammer head surface. If this continues for a long time, the surface of the crusher hammer will lead to further erosion. Furthermore, it will bond or mix with other materials, causing the risk of clogging the crusher.

Coal Gangue

Sandstones and shales are normally harder than coal gangue. They will increase abrasion wear and impact on the crusher hammer. More coal gangue will reduce the crusher’s working efficiency and reduce the crusher capacity. Some types of bluestone containing clay are also prone to forming clumps under moist conditions, such as when exposed to water, which can cause accelerated localized wear on the hammer heads or lead to blockages in the crusher.

Quartz Content

Larger, sharp quartz particles will cause severe cutting and grooving wear. Consequently, it increases wear on crusher hammer heads, the screen plates, or liners. If it mixes with clay, it not only causes the crusher to clog, but also increases the localized wear of the crusher hammer heads.

Raw Coal Particle Size

If the raw coal particle size is large, it will result in a higher impact load. We have to pay attention to the challenge of crusher hammer head hardness and impact resistance. If the quantity of fine powder is excessive, it will increase the friction on the hammer head, accelerating the wear on the crusher hammer head.

Foreign Object

If there are metal pieces mixed in with the coal, because the coal is softer and has a lower hardness requirement, when the crusher hammer strikes the metal pieces, it can easily cause the hammer head to crack or break. In severe cases, it can cause the crusher to stop, the rotor to vibrate, or the crusher to be damaged.

Feed Uniformity

If the material is fed unevenly, concentrated loads can cause localized wear, which can severely affect the crusher’s output and result in inconsistent particle size distribution.

Crusher Hammer Head Casting Site

Crusher Hammer Materials: Performance Advantages, Usage Limitations, and Suitable Operating Conditions

When we choose crusher hammer materials, we cannot choose materials that only have higher hardness, better wear resistance, or anti-erosion properties, and so on. We also need to know which failure issues each material can solve, when the condition should be used, and your operating conditions; only then can we know how to choose the right crusher hammer head for you.

The main failures of Crusher Hammer Heads for Coal-Fired Power Plants have: Normal wear, groove wear, spalling of the working surface, chipping, cracks, and sudden fracture.

High-manganese steel

The core advantage of high-manganese steel is its ability to absorb impact forces and inhibit crack propagation. It could form a hardened layer on the surface of crusher hammer heads, increasing hardness and impact resistance while maintaining better toughness. So it can solve problems such as crusher hammer cracks or breakage, large coal with high impact force, very significant feed coal sizes, and risks from foreign objects.
But the initial hardness is not the hardest. The hardest is formed after continuous impact. When the impact is insufficient, the surface does not harden sufficiently. In environments with low impact and high abrasion, relatively rapid and uniform wear may occur.

Alloy Steel

The types of alloy steel for coal crusher hammers that SUPER can provide include: Low-alloy steel, chromium-molybdenum alloy steel, box-martensite. The characteristic of alloy steel is that we can design the composition and heat treatment to achieve a flexible balance between hardness, strength, and toughness.
The problems of alloy steel that can be solved include: simultaneous impact and wear, excessive wear in high-manganese steel, and the risk of spalling in high-chromium cast iron being too high, among others. If you need more stable, predictable overall performance, we suggest using alloy steel.

However, the range of alloy steel materials is very broad, and performance varies significantly among the various grades. During processing, heat treatment has an obvious influence on its performance. As hardness increases, alloy steel’s hardness will decrease. If you are unsure whether to choose an alloy steel crusher hammer head, please contact our team. We will give you professional suggestions.

High-Chromium Cast Iron

High-Chromium Cast Iron crusher hammer head is mainly suitable for wear conditions. If your crusher hammer head has excessive wear and is prone to groove wear caused by quartz, sandstone, and coal gangue. Meanwhile, the coal feeding sizes are stable, and impact loads are under control. In that case, we suggest you use high-chromium cast iron crusher hammer heads. But the toughness of high-chromium cast iron crusher hammer heads is lower than that of high-manganese and most alloy steels. It is quite sensitive to large metal foreign objects and abnormal impacts.

Bimetallic Composite Materials

Bimetallic composite material is not a single material. SUPER uses a high-wear-resistant material on the hammer working end and a tougher material, cast iron, in the hammer shank. This is the structure of SUPER bimetallic composite material crusher hammer head. The basic principle is to use high-hardness, high-wear material in the working end area that contacts coal directly, and use good-toughness material in the shank and pin hole.

High Abrasion Resistance Crusher Hammer Blocks for Coal Crushing

Long-Life Crusher Hammer Heads for Power Plant Coal Crushers

High Impact Resistance Crusher Hammer Heads

Heavy-Duty Crusher Hammer Blocks for Industrial Crushers

High Chrome Crusher Hammer Heads for Coal Processing

Composite Wear-Resistant Crusher Hammer Heads

Replaceable Crusher Hammer Heads for Power Generation Systems

Compact Crusher Hammer Heads for Hammer Mill Applications

SUPER bimetallic composite material crusher hammer head is the ideal hammer head for Coal-Fired Power Plants. Its working end has ultra-wear resistance, and the pin hole and shank have strong resistance to repeated impacts. It solves the problem that a single material cannot meet both wear resistance and non-breakage requirements and addresses the drawback of standard hammer heads, which experience significant variations in stress and wear across different areas.

SUPER Foundry’s Casting Production Line

Quality Inspection

As one of the top coal-fired power plant crusher hammer head factory, SUPER enjoys very strong international brand recognition in the crusher hammer industry. SUPER has standardized and comprehensive quality inspection processes and standards. SUPER can consistently provide high-performance, reliable crusher hammers to power plant customers and crusher hammer spare parts distributors worldwide thanks to our rigorous quality control standards. SUPER inspects the quality from raw material, smelting, casting, heat treatment, machining, and inspection and testing of the final product. We control the entire production process and prioritize testing the elemental content in the raw materials and ingredients, dimensions, hardness, toughness, internal and surface defects, and bonding quality at the Interface of the Composite Region in Bimetallic Materials.

Raw Materials and Smelting Testing

We will inspect the raw materials’ purchasing records, purchasing testing certificates, compositions before casting, and spectral analysis after casting. Make sure the crusher hammer heads delivered to you meet our design requirements.

Casting

We have strict production requirements. We will accurately record casting temperature, casting time, Cylindrical, cap opening, and processes. Through our records and product quality control, we can control pinholes, slag inclusions, cracks, and other defects during casting, thereby improving the quality of our SUPER crusher hammer head and its stability.

Heat Treatment

We will check the heat treatment records and see if the treatment was conducted in strict accordance with the standards. Monitor for any abnormalities and assess whether they could affect the hammer’s properties. Maintain a clear, strict record of the furnace temperature profile, holding time, and cooling process. Make sure the hardness, toughness, and organization structure meet the design requirements.

Dimension Inspection

We will strictly adhere to the drawing’s requirements and inspect the hammer head’s shape, pinhole size and position, hammer thickness, and other specifications. We ensure that the crusher hammer heads manufactured by SUPER can be easily installed in your crusher and swing freely.

Hammer Mill Crusher Hammer Heads for Coal Crushing

Ring Hammer Crusher Heads for Power Plant Coal Crushers

Impact Crusher Hammer Heads for Power Generation Industry

Coal Crusher Hammer Blocks for Thermal Power Plants

Cleaning and Rough Processing

When we clean the surface of the crusher hammer after it comes out of the foundry furnace, we will inspect and record any cracks, deformations, or other obvious defects. Refer to these defects to identify the probable causes, and check whether products from the same batch have the same issue. We ensure that products in batches with quality issues do not reach your hands.

Property Inspection

We will test the hardness, impact toughness, mechanical properties, and microstructure. We also use ultrasonic testing and other non-destructive testing methods to check for any defects inside the hammer head.

A Corner of the SUPER Foundry

SUPER has strict batch testing requirements. Hammer heads from each batch are randomly inspected at a specified ratio, and samples are retained for record-keeping. We will also provide you with the relevant test records and supporting documentation for your records.

Crusher Hammer for Coal-Fired Power Plants | SUPER Manufacture