Recovering Lost Value: 200 T/H Spodumene Crushing Plant in Zimbabwe
How deploying 2PGY1500×1200 Hydraulic Roller Crusher controlled mineral sliming and unlocked peak flotation efficiency.
1. Client Challenge & Operations Deficit
Our client operates a fast-scaling hard-rock Spodumene ($Li_2O$) beneficiation site in Mashonaland East, Zimbabwe. Their fine-crushing secondary circuit initially utilized a standard configuration of high-speed cone crushers, which created devastating structural bottlenecks for their flotation plant:
• Severe Slime Waste: The dynamic impact of the old machinery pulverized the brittle lithium crystals, creating over 26% micro-fines (under 200 mesh). This created unrecoverable “mineral slime” that washed away into tailings.
• Rapid Liner Destruction: Spodumene’s extreme Mohs hardness (6.5–7) forced the client to execute expensive replacement maintenance on their cone liners every 25 days, causing severe downtime losses.
2. Upgraded System Architecture
Our plant engineering desk overhauled the line configuration by installing the 2PGY1500×1200 Heavy-Duty Hydraulic Double Roller Crusher outfitted with tungsten carbide studded roller sleeves.
By running at a controlled, low speed and exerting massive static hydraulic pressure, the new layout shatters raw lithium ore along natural intergranular crystal matrices. The discharge gap was secured at 5mm with high-pressure nitrogen gas accumulators providing continuous stabilization against incoming geological spikes.
3. Proven On-Site Transformation Data
Performance Parameters
Legacy Secondary Cone Crusher
2PGY Hydraulic Roller Crusher
Net Operational Gain
Tailings Slime Generation
26.4% useless dust (<200 mesh)
7.8% controlled size matrix
18.6% Material Saved
Flotation Recovery Rate
79.1% (Iron dust fouled surface)
83.3% (Pristine crystal profile)
+4.2% Absolute Yield
Liner Replacement Cycle
Every 22 to 25 Days
Exceeded 9 Months (Ongoing)
10X Longer Tooling Life
Downstream Milling Load
High power drawn (Smooth solids)
Dropped 24% (Micro-cracked feed)
24% Energy Savings
4. Field Director’s Verdict
“We were losing tons of high-grade lithium concentration to our tailings dam every shift because our cone setups simply pulverized the spodumene crystal structure into mud. The hydraulic roller solution completely stopped this over-crushing crisis. Furthermore, because it creates micro-cracks inside the cubic output, our primary ball mill output has expanded dramatically while reducing our monthly power bills.”
Our engineering team can simulate your specific spodumene or lepidolite mineral profile to determine the optimized hydraulic system parameters for your site.
