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Views: 0 Author: Site Editor Publish Time: 2025-10-11 Origin: Site
Severe Wear on (Wear Parts): Traditional impact crushers or hammer crushers face excessive wear when processing granite—hammer heads may need replacement every 100-150 hours, leading to monthly wear part costs of tens of thousands of yuan .
High Energy Consumption: Impact-based crushing requires enormous energy to break down granite’s dense crystalline structure, resulting in elevated electricity costs and reduced operational efficiency.
Strict Quality Requirements: Construction aggregates demand well-graded particles with low needle-like content. Improper crushing processes produce irregular particles that fail to meet industry standards.
Feeding: vibrating feeders deliver raw granite (0-800mm) uniformly to the primary crusher, preventing overload and ensuring steady production rhythm .
Pre-Screening: Built-in grizzly bars remove soil and fine particles upfront, reducing unnecessary wear on subsequent equipment and improving product purity.
| Crushing Stage | Key Equipment | Function & Advantage |
| Primary Crushing | PEW Jaw Crusher | Reduces 0-800mm raw ore to 100-200mm. Features heavy-duty jaws and hydraulic adjustment for high throughput and stable operation . |
| Secondary Crushing | Single-Cylinder Hydraulic Cone Crusher | Refines 100-200mm material to 30-50mm. Utilizes layer-pressing crushing to minimize wear and improve particle shape . |
| Tertiary Crushing/Shaping | Multi-Cylinder Hydraulic Cone Crusher / Roller Crusher | Produces final particle sizes (0-30mm). Roller crushers use static extrusion to save 30% energy vs. impact models and extend wear part life by 3-5x . |
Screening: vibrating screens separate materials into graded sizes (e.g., 0-3mm, 3-5mm, 5-10mm) with precision exceeding 95% . Oversized particles return to the tertiary crusher via conveyors, forming a closed-circuit system that guarantees product qualification.
Washing (Optional): For high-purity requirements, sand washing equipment removes dust and impurities from manufactured sand, producing washed sand (0-4.75mm) for premium concrete applications .
Dewatering & Storage: Dewatering screens reduce moisture content to below 15%, while sealed silos prevent secondary contamination during storage.
Configuration: Permanent installations with concrete foundations, integrating jaw crushers, cone crushers, and tower-type dry sand-making systems .
Advantages: High capacity (up to 600t/h) and low unit cost; ideal for large mines with stable ore sources.
Case Study: A fixed line in Shandong, China, combines dry and wet processing to produce 400t/h of manufactured sand and 200t/h of washed sand, supplying premium aggregates to infrastructure projects .
Configuration: Crawler/tire-mounted units integrating feeding, crushing, and screening (e.g., jaw mobile station + cone mobile station + screening mobile station) .
Advantages: No foundation required; commissioning in 1-2 days; easily relocatable to follow mining faces. PLC control systems enable one-click cavity cleaning and automatic iron protection .
Application: Ideal for small-to-medium mines, granite waste recycling, and remote construction sites. A crawler mobile line in China processes 150-200t/h of granite waste into 0-30mm aggregates for ready-mix concrete .
Dust Control: Fully enclosed equipment, negative-pressure dust collectors, and spray systems reduce dust emissions to below 10mg/m³, complying with global environmental standards .
Water Recycling: Closed-loop washing systems reuse 95% of process water, eliminating wastewater discharge.
Noise Reduction: Soundproof enclosures and low-noise motors limit operational noise to 75dB(A) or less.
Real-Time Monitoring: Sensors track crusher load, bearing temperature, and oil pressure, triggering automatic alarms for overload or malfunction .
Remote Control: Mobile apps enable parameter adjustment (e.g., discharge gap) and production monitoring from off-site, reducing on-site labor by 40%.
Predictive Maintenance: AI algorithms analyze equipment data to forecast wear part replacement needs, cutting unplanned downtime by 30%.
Crushing System: Inspect jaw plates, cone liners, and roller surfaces for wear; replace when thickness decreases by 50%. Lubricate bearings every 8 hours .
Screening System: Clean screen meshes daily to prevent clogging; check tension springs for fatigue.
Power System: For diesel-driven mobile units, monitor oil/coolant levels; for electric models, inspect cable insulation to avoid short circuits .
Wear Part Management: Use alloy steel wear parts designed for granite; stock critical components to minimize downtime.
Process Tuning: Adjust crusher discharge gaps based on particle size requirements—narrow gaps improve quality but reduce capacity, so balance is key.
Operator Training: Ensure staff master PLC controls and emergency procedures to avoid human error (e.g., excessive feeding).
Fully enclosed equipment to eliminate dust pollution;
Intelligent mining and crushing systems reducing resource waste by 15%;
Synchronized ecological restoration, turning mined areas into green spaces.
