The Problem: Flaky Particles & Excessive Fines

Limestone sand making at a medium-sized plant had long used a VSI crusher to process limestone (Mohs hardness 3-4, medium hardness). However, high-speed impact crushing caused two major issues for the process: first, flaky particle content reached 12%, affecting concrete workability; second, severe over-crushing generated over 25% of fines below 0.16mm, dropping the effective yield to below 60% – a large portion of raw material turned into waste dust while overloading the dust collection system.

Hydraulic Roll Sand Making Machine

Limestone Sand Making Solution: 2PGY Hydraulic Double Roll Crusher Replaces VSI

The plant replaced its VSI crusher with a Huashengming 2PGY1000×800 Hydraulic Double Roll Crusher for limestone sand making. Operating at low speed (≈70 RPM) with synchronized hydraulic pressure, the limestone is crushed within a packed bed along its natural bedding planes rather than by high-speed impact.

No iron contamination: The roll shells are made of high-chromium wear-resistant alloy – no metal flakes are peeled off, keeping the sand pure and white – a key benefit for limestone sand making.

Excellent particle shape: Compression crushing produces cubical particles. Flaky content drops below 5%, meeting Class I sand standards.

Controlled fines: By adjusting the roll gap (3–10 mm), fines below 0.16mm are kept within 10%, raising effective yield to 82%.

Energy saving: Energy consumption per tonne of sand falls from 6.0 kWh to 3.5 kWh, saving over 300,000 kWh annually.

Long wear life: Roll shells operate continuously for over 5,000 hours and can be field-hardfaced 2–3 times, dramatically cutting spare parts costs.

Results: Higher Yield & Lower Costs

After the upgrade, the plant’s sand production line runs stably, producing well-graded, cubical sand for limestone sand making. The customer reports a 20% reduction in concrete slump loss. Meanwhile, monthly maintenance costs have dropped by 65%, achieving both cost reduction and quality improvement.