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Project Case Study: Large-Scale Industrial Processing with Hydraulic Double Roller Crushers

Project Case Study: Large-Scale Industrial Processing with Hydraulic Double Roller Crushers
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Project Case Study: Large-Scale Industrial Processing with Hydraulic Double Roller Crushers
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Project Case Study: Large-Scale Industrial Processing with Hydraulic Double Roller Crushers

Global Project Showcase Project Case Study: Large-Scale Industrial Processing with Hydraulic Double Roller Crushers Maximizing mineral liberation and high-grade construction aggregate yield via advanced electromechanical-hydraulic integration technology. 1. Product Overview The Large Hydraulic……

  • Productive Capacity:4-500t/h
  • Finished Product Size:25-200mm
  • Included Equipment:
  • Hydraulic Double Roller Crushers

Global Project Showcase

Project Case Study: Large-Scale Industrial Processing with Hydraulic Double Roller Crushers

Maximizing mineral liberation and high-grade construction aggregate yield via advanced electromechanical-hydraulic integration technology.

1. Product Overview

The Large Hydraulic Double Roller Crusher is a high-efficiency, energy-saving intelligent crushing device engineered specifically for large-scale operations in mining, metallurgy, building materials, and modern solid waste recycling fields.

Integrating advanced electromechanical-hydraulic control loops, this machine adopts a heavy-duty hydraulic force distribution system to perform reliable medium and fine crushing of hard rocks and industrial materials. Featuring smart overload protection, adjustable discharge sizes, and durable wear-resistant roller shells, it ensures stable, high-capacity, and eco-friendly operation for heavy infrastructure worldwide.

Large Double Roller Crusher Operating On-Site

Large Double Roller Crusher Operating On-Site

2. Core Project Advantages

• Intelligent Hydraulic Protection System
The system automatically retreats the movable roller frame and resets instantaneously when encountering unbreakable foreign hazards (such as steel scrap or tramp iron), avoiding structural component damage and ensuring 24/7 continuous operation.
• High Crushing Efficiency & Energy Savings
By substituting dynamic impact force with high-pressure static extrusion, our units save 20% to 30% in operational energy consumption while expanding overall output limits by 30% to 40% compared to legacy crushing circuits.
• Elite Durability & Low Maintenance Costs
Roller skins are cast from premium high-chromium manganese steel alloys, yielding 3-5 times longer service life in harsh abrasive conditions. The smart layout uses modular roller components for swift, uncomplicated replacement.
• Adjustable Sizes & Superior Product Cube Shape
Real-time PLC controls modify the physical roller gap seamlessly, producing premium cubic finished product profiles with minimum elongated needle-flake fractions to meet rigid global gradation standards.
• Environmental Compliance & Enclosed Housing
Engineered with a fully enclosed structural framework combined with targeted dust collection setups, the crushing plant safely suppresses low-frequency noise and airborne particulates.

3. Working Principle

Designed for high-efficiency bulk material refining, our Large Hydraulic Double Roller Crusher operates on a high-performing static pressure extrusion principle. This physical mechanism ensures strict output sizes with optimized power consumption:

1. Feeding Process: Raw ores are uniformly directed from the upper feed bin into the main crushing chamber located precisely between the two horizontally aligned, counter-rotating rollers.

2. Material Engagement: Natural friction coefficients combined with structural gravity draw the feed rocks smoothly down into the narrowing pinch gap.

3. High-Pressure Crushing: As the rolls revolve, materials are subjected to intense, concentrated compression. When this targeted pressure exceeds the rock’s compressive limits, it fractures naturally along its weak boundaries.

4. Controlled Discharge: Separated particles cleanly fall down through the customizable bottom discharge slot, successfully ending the cycles with efficient laminar flow distribution.

4. Technical Parameters

Model Roll Diam. (mm) Roll Width (mm) Max Feed (mm) Capacity (t/h) Power (kw)
2PGY750×500 φ750 500 ≤40 20 – 30 2×(22-30)
2PGY800×600 φ800 600 ≤40 30 – 40 2×(30-37)
2PGY800×800 φ800 800 ≤40 40 – 50 2×(37-45)
2PGY1000×800 φ1000 800 ≤40 50 – 80 2×(45-55)
2PGY1000×1000 φ1000 1000 ≤60 80 – 100 2×(75-90)
2PGY1200×1000 φ1200 1000 ≤80 100 – 120 2×(75-132)
2PGY1500×1200 φ1500 1200 ≤120 150 – 200 2×(132-160)
2PGY1800×1000 φ1800 1000 ≤100 250 – 300 2×(250-315)
2PGY2000×1200 φ2000 1200 ≤120 300 – 400 2×(315-355)
Hydraulic Station & PLC Control Module setup

Hydraulic Station & PLC Control Module setup

5. Cross-Industry Deployment Scope

• Mining & Mineral Processing Industry: High-precision reduction of iron ore, copper ore, gold stone, limestone, and dolomite. Performs fine grinding operations upstream of ball mills to increase plant circuit liberation efficiency.

• Construction Aggregate Production: Supplies premium manufactured sand and fine gravel for highways, bridges, dams, and concrete batching lines requiring strict compliance with aggregate geometric cubicity.

• Building Materials & Cement Plants: Handles raw mill crushing, cement clinker reduction, coal gangue refining, and gypsum board material processing across synchronized building material lines.

• Energy & Metallurgy Circuits: Feeds pre-treated raw coal and coke to power stations and coking batteries, while managing industrial steel slag, furnace slag, and quicklime fine reduction.

• Solid Waste Recycling Plants: Breaks down raw concrete structures, brick fragments, mortar deposits, and industrial mineral tailings to accelerate resource regeneration and eco-safe solid waste recovery.

• Chemical & Ceramic Raw Materials: Provides controlled particle distribution for sensitive phosphate rock, industrial quartz, feldspar matrices, and highly abrasive refractory brick blends.

Request an Engineering Site Consultation

Our bulk material processing experts can calculate roller wear lifespans and draft custom layout blueprints according to your hardness metrics and target production rates.

Consult Our Project Engineers

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