Ore Crusher Preferred Roll Crusher. Roll crusher has become the core equipment for cost reduction and efficiency increase in mineral processing industry by virtue of its high efficiency crushing, precise particle control, energy saving, intelligent operation and maintenance and wide adaptability. In the future, with the deep integration of hydraulic technology and AI, its intelligent and wear-resistant performance will be further upgraded to promote the construction of ‘environmentally friendly mines’.
Ore Crusher Preferred Roll Crusher
The core advantages of roll crusher in the mineral processing industry are mainly reflected in its high efficiency crushing capacity, accurate particle size control, energy saving and environmental protection features and intelligent operation, etc. The following is the specific analysis:
1. High-efficiency crushing and precise particle size control
Squeeze crushing mechanism
Through the squeezing force, shear force and grinding force generated by the relative rotation of the double rolls, rapid crushing is achieved, with uniform discharged particle size (adjustable from 1-40mm) and significantly reduced over-crushing rate. The roll spacing can be flexibly adjusted by hydraulic system or shims to meet the requirements of particle size at different stages of beneficiation (e.g. coarse to fine crushing).
Improved crushing efficiency
With a processing capacity of up to 300 tonnes/hour, the crushing efficiency is improved by 30%-40% and energy consumption is reduced by more than 20% compared with traditional equipment. For example, in iron ore sand making, the finished product size can be precisely controlled at 1-5mm, with a high degree of particle regularity.
2. Energy saving and environmental protection with low operating cost
Optimisation of energy consumption and carbon emissions
The unit power consumption is as low as 2.4kW-h/tonne of ore, which significantly reduces carbon emissions. Hydraulic drive technology replaces the traditional mechanical transmission, power distribution is more efficient, long-term operation can save a huge amount of electricity costs.
Outstanding environmental performance
The sealed structure with dustproof plate reduces the dust leakage rate by more than 50%; the low-speed design keeps the noise below 85dB. Supporting the recycling of tailings (such as underground filling or paving), achieving the goal of ‘zero waste’.
Low maintenance cost
Wear-resistant rollers are made of high chrome alloy or tungsten carbide (hardness HRC60+), with a lifespan of more than 10,000 hours and a 30%-50% reduction in replacement frequency. Modular design shortens the maintenance time by 50% and reduces downtime loss.
Ore Crusher
3. Intelligent and automated operation
Real-time parameter adjustment
Hydraulic system with intelligent control can automatically adjust the roller pitch, pressure and speed according to the hardness of the material and feed size to avoid overloading or idling. For example, the fully automated model of WMS supports remote monitoring and mobile phone app operation, realising ‘one person, many machines’ management.
Fault warning and data management
Built-in sensors monitor the material level, temperature and other parameters to warn of potential faults in advance, increasing maintenance response speed by 50%. Data-based production management optimises the process and improves the efficiency of downstream processes.
4. Wide Adaptability and Economy
Strong material compatibility
is suitable for more than 200 kinds of materials, including high hardness ores (iron ore, quartz stone), wet viscous minerals (mud-bearing ores) and industrial waste (steel slag, furnace slag). Special roll surface design (e.g. with scraper) can handle viscous minerals and avoid roll sticking.
High ROI
Flexible equipment prices (e.g. 2PG series) are affordable for small and medium-sized beneficiation plants; operating costs have been significantly reduced, with a case study of an iron ore plant showing a 50% reduction in energy consumption of ball mills, saving more than a million dollars annually. Small footprint, easy to deploy the production line.
