Shanxi Lingqiu County Xiyue New Building Materials Ultra-fine Crushing Roll Crusher Project
Lingqiu County Xiyue New Building Materials Project Introduction:
The raw materials for this project are a mixture of muck (containing slurry stone) and coal gangue. The coal gangue is crushed using a hammer + screen method with a 2.5mm screen aperture. The muck is processed through two-stage screening plus a soil kneading machine for material selection. The muck contains a high amount of slurry stone. To ensure production capacity, the trommel screen aperture is set to 8mm, but capacity remains insufficient due to wet material and the abundance of slurry stone. The process flow is as follows:
Project issues:
The mixture contains many slurry stone particles, making brick surfaces prone to cracking and brick stacks prone to collapsing.
Although the screen mesh is 8mm, clay in the rainy season tends to clog the drum screen, causing high recirculation after screening, severe energy consumption in the raw material line, and low output (around 50 tons/hour).
The forming section of this production line uses a standard double-roller mill for material crushing. Due to the presence of considerable sandy, high-hardness materials, the standard roller mill lacks sufficient extrusion strength and roller gap, making it difficult to break down particles, resulting in no fine powder and insufficient raw material plasticity.
The project renovation plan is as follows:
Solution Description: Remove the second easily clogging drum screen and the inefficient soil kneader, replacing them with two roller crushers. Set the first drum screen to 3–4 cm, primarily to remove large lumps and grass roots. The second roller crusher reduces 3–4 cm material to below 8 mm in one pass. The third roller crusher further reduces material from 8 mm to approximately 1.8 mm.
Reason for designing these two devices:
1. The counter-roll crusher with a mud-scraping device solves the issue of fine crushing wet materials, and the ultra-fine counter-roll crusher features differential speed on its two rollers, which effectively grinds and kneads materials, reducing particle ratio and greatly increasing powder output, thereby enhancing raw material plasticity.
2. The original screening method produced too much waste, requiring at least several truckloads of scrap daily. With this new approach, all materials under 4cm can be utilized, significantly reducing waste and saving costs.
3. The original plan only screened clay through 8mm holes without crushing granular materials. The ordinary roller press in the main forming section lacks sufficient extrusion and crushing force, so the roller press before the feed bin should be an ultra-fine crusher, not a standard one, to grind and break the shale-clay and coal gangue mixture, greatly reducing particle size to around 2mm for optimal forming results.
4. Since the gap of the last roller mill before the main machine is controlled at around 1.8mm, and its crushing and grinding effect on materials is significant, the previous rollers before the main machine are no longer functional and can be stopped to save electricity.
5. The ultra-fine roll crusher is insensitive to material moisture, with wet or dry feed not affecting capacity. After upgrades, the raw material line now produces no less than 90 tons per hour, reducing working hours from 20 to 12, significantly saving labor and electricity costs.