Different types of mineral sizers are optimal for distinct crushing needs
Introduce
Mineral Sizers are an integral part of the mining and mineral processing industry, where their efficient crushing performance has a direct impact on productivity and product quality. Whether it’s hard ores, sticky materials or high-volume industrial requirements, Mineral Sizers play a key role in ensuring uniformity and reducing energy consumption.
However, crushing requirements vary greatly depending on material properties, throughput and application scenarios, and there is no one size fits all. Different models are tailored to specific materials and crushing requirements, from low-speed, high-torque designs to heavy-duty models for larger materials, each with its own unique advantages.
The purpose of this article is to provide an in-depth look at the features of each mineral screen model and its optimal application for different crushing needs, helping you to optimize productivity and reduce operating costs by selecting the most suitable model based on material characteristics, crushing requirements and throughput.
Primary Mineral sizers
As the first core equipment of mining crushing operation, Primary Mineral Screen Crushers, with powerful coarse crushing capacity, are responsible for the rapid processing of primary ore into medium-sized materials after mining.
The series includes 4 models, 2PLF800, 2PLF1000, 2PLF1200 and 2PLF1500, each with a step-up in core parameters to meet the crushing needs of mines of different sizes:
Teeth Roller Dia
increases from 800mm in 2PLF800 to 1400mm in 2PLF1500. The large diameter rollers not only increase the crushing force, but also can cope with quartzite, granite and other high hardness ores, for example, when processing iron ore with hardness coefficient f=12-14, the large rollers of the 2PLF1500 can effectively reduce the wear and prolong the service life of the equipment.
Roll length
There is a significant difference in roll length between the 2PLF800 and the 2PLF1500, with the 2PLF800 having a roll length of 1500-2500mm and the 2PLF1500 having a roll length of 2000-3500mm. Longer roll lengths mean a larger crushing contact area, and in continuous mining scenarios, the 2PLF1500 can increase the amount of material crushed in a single pass by 40%. In a continuous mining scenario, the 2PLF1500 can increase the amount of material crushed in a single pass by as much as 40%, significantly increasing productivity.
Max feed size
This parameter is proportional to roll diameter, increasing from 800mm to 1500mm. Designed to handle the bulk of ore from blasting, the 2PLF1200 is capable of crushing up to 1200mm diameter raw ore in metal mining, reducing pre-processing and overall costs.
Output size
All models are controlled at ≤300mm, crushing raw ore to a medium size for subsequent processing. This size range meets the feed requirements of the secondary crusher while avoiding over-crushing and reducing energy losses.
Capacity
The capacity has been increased from ≤2000 t/h for the 2PLF800 to ≤10000 t/h for the 2PLF1500. In large-scale mines of 10 million tons, the 2PLF1500 can be combined with a belt conveyor to form a high-efficiency crushing system that can realize 24-hour uninterrupted operation and ensure continuous supply of ores.
Secondary Mineral sizers
Secondary Mineral sizers are the key fine processing equipment after primary crushing, by further refining the material size to meet the stringent requirements of downstream industries.
The 2PLS600, 2PLS800, 2PLS1000 and 2PLS1200 models are designed around the needs of fine crushing:
Teeth Roller Dia
ranges from 600mm to 1200mm in diameter, which is more compact than the primary models. This design ensures sufficient crushing force and improves the adaptability of the machine to the initially crushed material, while the 2PLS1000 achieves efficient fine crushing through high-frequency crushing when processing sandstone from the primary crusher.
Roll length
Roll length ranges from 1000 to 4000 mm, increasing gradually as the model is upgraded. Longer roll length can realize multiple crushing of materials. In the production of building materials, 2PLS1200 can extend the residence time of materials in the crushing chamber by 30% with 4000mm long roll length, which can significantly improve the uniformity of particle size.
Max feed size
The feed size is controlled at 200-400mm to accurately take up the discharge from the primary crusher. This size range not only makes full use of the primary crushing results, but also avoids the impact of oversized materials on the equipment. In the metallurgical industry, the 2PLS800 can stably process iron ore below 300mm, providing high quality raw materials for the subsequent grinding process.
Output size
The output size ranges from 50-140mm, which varies slightly from model to model. 2PLS600 is suitable for the scenarios with high requirements on particle size, which can crush the materials up to 50-80mm, while 2PLS1200 realizes a wide range of particle size from 50-140mm through the structure of multi-stage crushing, which meets the needs of different downstream users.
Capacity
The capacity of 250-4000 t/h is perfectly matched to the discharge flow of the primary crusher. In the whole crushing line, the secondary crusher is designed with a reasonable capacity to avoid material accumulation and ensure stable operation of the system. For example, in an ore processing plant with a daily capacity of 10,000 tons, the 2PLS1000 can be combined with the 2PLF1200 to form a highly efficient crushing combination for continuous operation of the entire process.
Factors to consider when selecting a mineral sizer model
Characteristics of the material
Hardness
Mineral sizer suitable material hardness coefficient f ≤ 8, such as coal, limestone and other materials, if the material is too hard, the wear and tear of the rollers and the frequency of replacement will be significantly increased, affecting the economy and service life of the equipment, but also prone to jamming of the material.
Viscosity
Viscous materials (such as clay, wet coal sludge) are easy to adhere to the rollers, you need to choose the “sharp teeth + sparse pitch” design (to reduce the contact area), and increase the roller surface cleaning device; non-viscous materials (such as sandstone, dry coal) on the teeth of the adaptability of the stronger
Impurity rate
If the material contains metal impurities (such as rebar, nails, common in construction waste), will seriously damage the rollers (teeth chipped), need to be separated in advance through the removal of iron; if containing fiber impurities (such as wood, plastic), may be entangled rollers, need to be cleaned manually
Material water content
If the water content is too high, the material will be easily adhered to the surface of rollers or block the discharge gap during crushing; if the water content is too low, it will easily generate dust during crushing, but it will have less effect on the crushing ratio.
Material size
Feed size
If the inlet size exceeds the maximum inlet size of the equipment, the material may not be able to enter the crushing chamber between the two rollers smoothly, resulting in the phenomenon that the material is stuck between the rollers or teeth, leading to the interruption of crushing and the need to stop and clean up, which will seriously reduce the crushing efficiency.
If the feed size is too small, there will be excessive crushing, which will easily produce too much powder, which not only wastes energy, but also may affect the normal rotation of the rollers due to the accumulation of materials, thus reducing the processing efficiency.
Output size
The size of the crushed product determines the design of roll diameter and pitch, tooth shape and tooth spacing.
Roll Diameter and Pitch
If the finished product size is small (e.g. below 50mm), the roll pitch should be reduced (the smaller the roll pitch, the finer the material), and a larger diameter roll may be needed to ensure the crushing force; if the finished product size is large (e.g. above 100mm), a larger roll pitch can be used, and the roll diameter can be appropriately reduced.
Tooth shape and pitch design
When the finished product size is small, fine tooth shape (such as pointed teeth, small pitch teeth) should be adopted to realize fine crushing through inter-tooth shear and extrusion; when the finished product size is large, coarse tooth shape (such as wide teeth, large pitch teeth) can be adopted to reduce the over-crushing of materials.
Conclusion
The selection of the Mineral sizer should be closely related to the crushing requirements and material characteristics, and should focus on the hardness, viscosity, moisture content and other characteristics of the material, as well as the feed/discharge size and production capacity: hard materials are preferred to choose a large roll diameter models, viscous materials need to be configured with an anti-sticking structure, and at the same time need to match the production capacity of the pre-process crushing process and the particle size.
Reasonable selection can reduce equipment wear, avoid material clogging, and improve the stability and economy of the crushing system.
