As a country rich in mineral resources, Kazakhstan ranks among the world’s leading nations in terms of reserves of iron ore, coal and other resources. The local mineral processing industry has a strong demand for briquetting equipment, particularly for efficient, reliable briquetting production lines capable of operating in harsh, cold climates. We use these lines to compress powdered materials such as iron ore and coal into briquettes, thereby addressing issues such as loose material, high transport losses and severe dust pollution, whilst improving material utilisation and transport efficiency. The client for this collaboration is a major local coal processing enterprise in Kazakhstan, specialising in the processing and export of coal powder. The traditional briquetting equipment previously used had low production capacity (only 20 tonnes per hour) , an unstable pelletisation rate and high energy consumption. Furthermore, the equipment was unable to cope with the local cold climate, resulting in frequent breakdowns that severely impacted production schedules and product quality. There was an urgent need for a high-performance, customised 50-tonne-per-hour pelletising production line to achieve efficient, continuous and stable production, whilst meeting local environmental and energy-saving requirements.
Solutions
Taking into account the client’s specific requirements, local operating conditions and the characteristics of coal mine materials, Zhongya Machinery has designed a bespoke 50-tonne-per-hour fully automatic briquetting production line. This comprehensive solution covers the entire process from ‘raw material processing’ through ‘compression and moulding’ to ‘finished product conveyance’ and ‘drying’. We have optimised the core equipment for operation in sub-zero temperatures, ensuring a balance of production capacity, efficiency and reliability. The detailed proposal is as follows:
Core Equipment Configuration
The custom-built pelletiser from Zhongya Machinery is selected as the core equipment, complemented by a hammer crusher, twin-shaft mixer, conveyor and drying equipment to form a complete production line. The briquetting machine features wear-resistant alloy forged rollers, with the main shaft undergoing 40Cr tempering treatment to ensure high strength and a long service life. The hydraulic system maintains stability and allows us to adjust pressure according to material characteristics, enabling efficient forming. The resulting briquettes have high density and excellent strength, meeting the requirements for transport and subsequent smelting.
Optimisation for Operating Conditions
In response to the harsh, cold climate of Kazakhstan, the production line equipment has undergone specialised modifications. We have optimised the sealing structures and hydraulic systems, and selected low-temperature-resistant components to ensure the equipment can start up and operate continuously even at temperatures as low as -20°C. This prevents issues such as equipment jamming or malfunctions caused by low temperatures, thereby safeguarding production continuity.
Guaranteed Capacity and Efficiency
The entire production line is designed with a capacity precisely matched to the client’s requirement of 50 tonnes per hour. It employs a fully automated control system to achieve automated operation throughout the entire process—from raw material feeding, crushing, mixing, pelletising, conveying to drying—thereby reducing manual intervention and lowering labour costs. We have optimised the transmission system to reduce energy consumption, achieving energy savings of over 20% compared to the client’s existing equipment. Concurrently, we enhanced production efficiency, ensuring a stable average daily output of approximately 500 tonnes to meet the client’s large-scale production requirements.
Feedback
Since the production line was commissioned. it has fully met the client’s expectations. The client has spoken highly of Zhongya Machinery’s product quality, customisation capabilities and service standards. Specific feedback is as follows:
Production capacity and stability meet requirements:
The production line’s actual operating capacity has stabilised at 50–52 tonnes per hour, with an average daily output exceeding 500 tonnes, thereby meeting the demands of large-scale production; The equipment is well-suited to the local sub-zero operating conditions, running continuously without faults in low-temperature winter environments. The fault-induced downtime rate is below 1.5%, significantly lower than the industry average. This has completely resolved the previous issues of insufficient production capacity and frequent breakdowns, with production efficiency increasing by over 60%, thereby effectively ensuring product delivery schedules.
Superior product quality:
The pressed pellets feature a smooth surface, uniform density and high compressive strength. There is no fragmentation during transport, with a breakage rate of less than 0.5%, fully meeting subsequent smelting and export standards, thereby significantly enhancing product value. Since we do not require any binders, this both reduces production costs and ensures pellet purity. This also helps us earn unanimous recognition from downstream customers.
Professional and Efficient Service:
The technical team at Zhongya Machinery responds promptly, carries out installation and commissioning efficiently, and provides thorough training. They also offer professional after-sales maintenance services.. They are able to swiftly resolve any issues encountered during production, requiring minimal involvement from the client throughout the process. The equipment is simple to operate and highly automated, significantly reducing labour costs and enhancing production management efficiency.
Currently, the production line has been operating stably for over a year. The client highly values Zhongya Machinery’s products and services, and has agreed to a long-term partnership. They plan to add new production lines in the future and continue to select equipment from Zhongya Machinery to support the expansion of their production scale and enhance their market competitiveness.
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