Hydraulic Double Roll Crusher for High-Quality Basalt Sand Making
Hydraulic Double Roll Crusher for High-Quality Basalt Sand Making
Project Background A comprehensive mineral processing plant in Southeast Asia mainly processes mixed ores of copper ore, magnetite and weathered basalt. Its original fine crushing section adopted impact sand makers, which brought multiple long-term operational pain points. The ores are relativ……
- Productive Capacity:20-400t/h
- Finished Product Size:<5mm
- Included Equipment:
- ore sand making machine
Project Background
A comprehensive mineral processing plant in Southeast Asia mainly processes mixed ores of copper ore, magnetite and weathered basalt. Its original fine crushing section adopted impact sand makers, which brought multiple long-term operational pain points. The ores are relatively hard and cause rapid wear of hammers and liners, requiring at least two shutdowns every month for spare part replacement. High-speed impact generates massive ultra-fine slime, leading to the loss of valuable minerals in tailings and failing to reach the target mineral recovery rate. The finished particles contain abundant flaky fragments, imposing heavy load on the subsequent ball mill and resulting in high overall energy consumption.
After comparing equipment manufacturers extensively, the customer selected customized hydraulic double roll ore sand makers from Huashengming to build a two-stage fine crushing and sand making production line, which balances mineral dissociation, aggregate shaping and stable continuous operation.
ore sand making machine
Overall Production Line Configuration
- Primary Coarse Crushing: Jaw crusher, crushing raw ores into uniform feedstock of 30–50mm
- Core Fine Crushing & Sand Making: Huashengming hydraulic double roll ore sand maker. Its roller skins are integrally molded of high chromium manganese alloy via centrifugal casting technology.
- Auxiliary Equipment: Vibrating feeder, belt conveyor, linear vibrating screen, anti-sticking scraper assembly
- Technological Process: Raw ore coarse crushing → uniform feeding into double roll sand maker → extrusion fine crushing and screening → finished ore sand divided into two streams: one for flotation mineral separation, the other processed as industrial aggregates for sales.
Core Operation Improvements On Site
1. Centrifugal Cast Wear-Resistant Roller Skins Greatly Reduce Spare Part Replacement Frequency
The core roller skins are manufactured through centrifugal casting, featuring dense internal metal structure and uniform thickness of wear-resistant layers. Their friction and impact resistance against ores far outperforms ordinary sand-cast roller bodies. The roller skins suffer slight abrasion and do not require frequent surfacing repair. Compared with the original impact equipment, the comprehensive service life of wear parts is extended by over 3 times, drastically cutting production loss caused by shutdown maintenance.
2. Laminated Extrusion Crushing Effectively Reduces Over-Grinding and Improves Mineral Recovery Rate
Abandoning high-speed impact mode, the machine cracks ores through low-speed high-pressure laminated extrusion of twin rollers. Ores split along natural textures, avoiding grinding valuable metal minerals into ultra-fine slime hard to recycle. The proportion of slime drops significantly, the retention rate of metals in flotation rises remarkably, and the loss of metals in tailings is greatly alleviated. The output of concentrates increases steadily under the same raw ore feeding volume.
3. Hydraulically Adjustable Roll Gap Enables Flexible Production Switching for Various Ores
The production line alternately processes three materials: copper ore, magnetite and hard basalt. Equipped with an automatic hydraulic roll gap adjustment system, operators can adjust the clearance with one click according to ore hardness and finished particle size requirements. It can produce 0–5mm fine sand for mineral separation and 5–16mm construction aggregates simultaneously. A single production line fulfills both mineral separation and aggregate sales demands and simplifies the production layout.
4. Automatic Hydraulic Retreating Protection Prevents Host Damage Caused by Stuck Hard Objects
Mined ores are often mixed with iron blocks and extra hard surrounding rock lumps, which easily jam conventional crushers and damage transmission components. This machine is fitted with a hydraulic buffer retreat system. When uncrushable foreign matters enter the crushing chamber, the movable roller automatically retreats to discharge materials and resets quickly after foreign matters are removed. No manual shutdown cleaning is needed in the whole process, core components including reducers and roller bodies are well protected, and the equipment failure rate is greatly lowered.
Working Principle of Ore Sand Making Machine
5. Built-In Anti-Sticking Scraper Structure Ensures Stable Processing of Dry and Wet Ores
Raw ores mined in the mining area carry surface mud and tend to stick to roller surfaces when slightly damp on rainy days. The roller surfaces are optimized with anti-slip and anti-sticking design, matched with built-in scrapers. Muddy and damp ores can be fed smoothly without unstable particle size output or machine blockage, supporting round-the-clock non-stop operation.
Customer Feedback On Site
The person in charge of the mineral processing plant stated that after switching to Huashengming hydraulic double roll ore sand makers, the overall operation and maintenance cost of the fine crushing section dropped obviously, eliminating monthly shutdowns for wear part replacement. The reduction of over-ground slime helps the plant hit the standard mineral recovery rate. The equipment is easy to operate, and local workers can master independent operation after short-term training. The whole set of equipment fits the existing plant space without large-scale civil engineering renovation, and the payback period after production meets expectations.
Project Summary
To meet the processing demands of high-hardness, highly abrasive metal ores with strict limits on over-grinding in mineral separation, Huashengming hydraulic double roll ore sand maker adopts three core designs: centrifugal cast wear-resistant roller skins, laminated extrusion crushing and hydraulic safety protection. It solves common industry drawbacks of traditional sand making machines such as fast wear, mineral loss and unstable operation. Suitable for fine crushing and sand making sections of iron ore, copper ore, basalt and various weathered ores, it serves as a preferred supporting equipment for medium and small mineral processing plants and aggregate mines to boost product quality and cut production costs.
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+86-13838144666
+86-13838144666
