How a medium sand plant used the 2PGY1000×1000 hydraulic roll crusher to efficiently crush abrasive river pebbles, cut energy use, and lower operating costs。

Project Background & Challenge

A plant producing 800,000 t/year of manufactured sand had long processed river pebbles (Mohs hardness >7, high silica). Before the roll crusher, it used a three‑stage process: jaw, cone, and VSI crusher. Three major problems existed:

High energy: The VSI (2×200 kW) consumed >6.5 kWh per tonne of sand, accounting for >45% of plant power.

Poor particle shape & excessive fines: Flaky particles reached 18%, and fines exceeded 15%, hurting concrete workability and requiring extra dedusting.

Short wear life: Highly abrasive pebbles forced wear tip and liner replacement every <80 hours. Monthly spare parts cost >RMB 40,000, and line availability fell to 70%.

Live Production Footage of Roll Crusher

The plant replaced the VSI with one 2PGY1000×1000 roll crusher (roll diameter × width: 1000×1000 mm, two 132 kW motors). Material (<30 mm from cone crusher) is crushed by static compression between the two rolls:

Dual motor drive + hydraulic system: Two 132 kW motors drive fixed and moving rolls in opposite rotation. An intelligent hydraulic cylinder adjusts the gap (1–8 mm steplessly). Material is compressed at up to 300 MPa, fracturing along grain boundaries with micro‑cracks – pure interparticle crushing, no metal impact wear.

Wear‑resistant roll surface: Hardfaced rolls (≥HRC62) with profiled stripes for better draw‑in. On high‑silica pebbles, wear is only 2.5 mm per 1,000 hours. Rolls can be rebuilt on‑site 3–4 times, total life >8,000 hours – eliminating weekly VSI part changes.

Verified Performance

After integrating the 2PGY1000×1000, six months of operation showed:

38% lower energy consumption: From 6.5 kWh/t to 4.0 kWh/t. On 800,000 t/year, saving 2 million kWh/year, or ~RMB 1.4 million.

92% premium sand product: 0–5 mm sand contains only 6% flaky particles; fines controllable below 10% by adjusting gap and roll speed. Meets GB/T 14684 Class II standard, concrete slump loss reduced by 30%.

Stable 150–170 t/h: Steady 160 t/h on 25 mm feed – a 33% increase from the VSI’s 120 t/h, without choking or over‑crushing.

No grinding media, lower maintenance: No steel balls, rods, or impact wear parts. Main consumables are roll hardfacing (rebuildable) plus hydraulic filters and oil. Monthly maintenance costs 85% lower than VSI.

Dust‑tight & quiet: Labyrinth seals + pulse dust collector port, with plant negative pressure system – workshop dust <3 mg/m³. Enclosed sound hood reduces noise to 82 dB(A) (passive insulation), well below national limits.

Summary: Replacing impact sand making with static interparticle roll crushing cut energy and maintenance costs while improving product quality and line stability – a proven upgrade for hard, abrasive rock.

Technical Parameters of Double Roll Crusher