Global Mining Performance Case

Why a Customer in Luohe, Henan Switched from a Reversible Hammer Crusher to a G1208 HPGR for Crushing River Pebbles

Project Background & Original Pain Points

A building materials company in Luohe, Henan replaced its years‑old sand making machine with a G1208 High Pressure Grinding Roll (HPGR). Why?
The company had long been using a reversible hammer crusher to process river pebbles (Mohs hardness >7, high silica content) instead of the G1208 HPGR. As a highly abrasive material, river pebbles caused extreme wear on the equipment. The company faced three core pain points:

• Frequent hammer and liner replacement: Due to the high hardness of river pebbles, the hammer crusher’s hammers and liners needed replacement every less than 150 operating hours. Each replacement required up to 8 hours of downtime, seriously affecting production continuity.

• High spare parts cost: Monthly consumption of hammers and liners exceeded RMB 40,000. Added to the labor and capacity losses from frequent shutdowns, the cost per tonne of crushing was nearly 40% above the industry average.

• Low yield and excessive fines: The reversible hammer crusher relies on high‑speed impact, which tends to generate a large amount of ultrafine powder (below 0.16mm accounting for >20%). This not only reduces effective yield but also increases the dust removal load, and the resulting particle shape is flaky, affecting downstream use.

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  G1208 High Pressure Grinding Roll live on-site shot

Solution – Switching to the G1208 High Pressure Grinding Roll (HPGR)

After thorough evaluation, the customer decided to purchase our G1208 HPGR. Key parameters:

• Motor configuration: Two 250 kW motors, independent dual‑motor drive – ample power and smooth operation.

• Capacity: 300–400 tonnes per hour, meeting large‑scale production demands.

• Yield: For river pebbles, the yield is stable at 70%–80%, far higher than the actual yield of the hammer crusher.

• Working principle: Interparticle compression crushing. Material is subjected to high‑pressure static compression between the two rolls, fracturing along natural cleavage planes and generating micro‑cracks – not by high‑speed impact – greatly reducing over‑crushing.

Core Advantages – Solving the Fundamental Defects of Hammer Crushers

Compared with the reversible hammer crusher, the G1208 HPGR delivers qualitative improvements in several aspects:

• Greatly extended wear part life: The roll surface is protected by a high‑wear alloy overlay (hardness ≥HRC60). When processing river pebbles, each pair of roll shells can operate continuously for 2500–3000 hours, and can be field‑rebuilt by hardfacing 2–3 times without loss of wear resistance, achieving a total service life of 8000–10,000 hours. This completely eliminates the “replace hammers every few days” headache.

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  G1208 High Pressure Grinding Roll production site

• Drastically reduced operating cost: Although the installed motor power is slightly higher than the original hammer crusher (2×250 kW vs 2×200 kW), the energy consumption per tonne of finished product is actually lower, because wasted impact energy and over‑crushing energy are greatly reduced. Together with an 85% reduction in spare parts consumption, the comprehensive crushing cost is reduced by about 50%.

• Good particle shape, controllable fines: The sand produced by the HPGR is cubical, with flaky particle content below 8%. By adjusting the roll gap (6–20 mm adjustable), fines below 0.16mm can be controlled within 10%, and the yield is stable at 70%–80%, meeting high‑quality manufactured sand specifications.

• Stable operation, low noise: The machine has a fully enclosed structure, equipped with spring vibration‑damping bases and modular sound enclosures, effectively suppressing vibration transmission and noise leakage. Workshop dust concentration and operating noise are far superior to those of the hammer crusher.

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  G1208 High Pressure Grinding Roll sand making site

Customer Feedback & Current Status

The customer commented: “With the hammer crusher, our workers dreaded changing hammers – it was tiring and disrupted production. Now with the HPGR, we hardly need to worry after startup, and the yield is high. This machine is definitely worth it.”

Currently, this G1208 HPGR is operating stably at the customer’s site in Luohe, Henan. The equipment was commissioned smoothly, and the yield, energy consumption, and operating costs have all met expectations. We wish our customer continued success and prosperity!

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