Roll crusher has excellent performance in crushing basalt, especially in particle size control, wear resistance and energy efficiency, but also need to be based on the characteristics of basalt (such as hardness, abrasive) reasonable selection and configuration.
Crushing efficiency and capacity advantages
High-efficiency crushing mechanism:
Roll crusher crushes basalt rock by double-roll high-pressure extrusion (pressure up to 150-200MPa) and shear force, with high energy utilisation and crushing ratio up to 5-8. Compared with impact crusher, its low rotational speed and high pressure working mode reduces the energy consumption by 30-40%, and the power consumption per unit is only 0.8-8%. The unit power consumption is only 0.8-1.2kWh/t.
High capacity adaptability:
The production capacity is stable at 50-200 tonnes/hour (e.g. 2PGY1000×800 model) when processing basalt, and the capacity of large-sized equipment (e.g. 2PGY1500×1000) can reach 300 tonnes/hour, which can satisfy the demand of large-scale production.
Finished product quality advantages
Accurate control of particle size:
Hydraulic system dynamically adjusts the roller gap (0.5-5mm adjustable), the error is ≤ 0.1mm, the uniformity of the finished product particle size of more than 95%, the rate of over-crushing <5%. Basalt particles after crushing are mostly cubic, with low needle flake content (<10%), in line with GB/T 14685 construction aggregate standards.
Gradeability:
The fineness modulus of finished sand is stable at 2.3-2.6, which is suitable for high grade concrete and road base material.
Durability and Stability
Ultra-high wear-resistant design:
The rolls are coated with high chromium alloy (hardness HRC62+) or tungsten carbide, which improves the abrasion resistance by 3 times, and the service life is up to 1-3 years (abrasion rate <0.1mm/thousand tonnes).
Intelligent protection system:
Overload automatic yielding: hydraulic system automatically lifts the roller to discharge the material when encountering metal impurities or super-hard materials to avoid jamming.
Real-time fault warning: PLC system monitors vibration, temperature and other parameters, and automatically adjusts or stops the machine when abnormal.
Convenience of operation and maintenance
Automation control:
one-key start and stop, automatic adjustment of parameters (such as feed speed, roll gap), only one person to operate.
Modular maintenance:
Side-opening design facilitates the replacement of roller skins, centralised lubrication system extends bearing life, and the maintenance cycle is extended to 500 hours/time.
Environmental performance
Low dust and noise:
closed structure + dust removal interface, dust emission <10mg/m³, noise ≤ 85dB (better than impact crusher > 100dB).
Energy saving and consumption reduction:
Energy consumption is 20-30% lower than that of jaw crusher, which meets the standard of green mine.
Ability to handle special working conditions
Sticky and wet material compatibility:
Anti-sticky roll design (such as adding scraper) can handle basalt with humidity ≤ 8%, to avoid clogging.
Compatibility of materials containing impurities:
With the pre-screening of iron remover, it can handle basalt containing small amount of metal impurities.
Limitations and conditions of application
Feed size limitations:
Maximum feed size is usually ≤ 50mm (some models support ≤ 100mm), need to be preceded by coarse crushing equipment (such as jawbreaker).
Hardness adaptability boundary:
For very hard basalt (compressive strength >250MPa) or high quartz content rock, need to be matched with high configuration roll skin (such as tungsten carbide).
With the three core advantages of high-pressure and precise crushing, wear-resistant and long life, energy saving and environmental protection, the roll crusher has become an ideal choice for efficient sand production from basalt, especially suitable for projects sensitive to finished product particle size and energy consumption.
