Key features of our mineral sizer machines
Introduce
For a long time, people have broken rocks by squeezing, rarely using more reasonable methods such as stretching and shearing. However, our mineral sizer is designed based on the principle of rock shear failure. That is to say, by applying a shear force to the rock, the rock is subjected to the shear force and the bending torque generated by the shear force, thereby shearing or breaking the rock. Another important reason is that most rocks themselves have lattice defects and texture defects, which make them prone to fracture along the directions of defects, textures, and joints when subjected to shear forces. The breakthrough of Mineral sizer in the theory of crushing has given it a significant advantage in performance.
A comparison between Mineral sizer and traditional crushers
The working principle and limitations of traditional crushers
Gyratory crusher, jaw crusher
This type of crusher adopts the working principle of extrusion crushing. Through the periodic movement of the moving cone or the moving jaw, it applies impact pressure to the material, forcing it to be crushed under the extrusion action. In practical applications, to achieve effective crushing, an extremely large crushing force must be applied to the materials. This leads to the need for heavy frames and high-strength components in the structural design of the equipment, making the entire machine bulky and astonishingly heavy. In addition, due to the significant energy loss during the transmission process, such equipment generally has the problem of low crushing efficiency. Its production capacity per unit time is only 60% to 70% of that of the new equipment of the same specification. At the same time, its energy consumption is 20% to 30% higher than the industry average, and the operating cost remains high.
Impact crusher, hammer crusher
The material entering the crushing chamber is crushed by high-speed impact through the impact area formed between the high-speed rotating hammer head (with a linear speed of up to 70-90m/s) and the impact plate. Although this high-kinetic working mode can achieve a relatively large crushing ratio, it also brings significant drawbacks: the high-speed rotating hammer heads and impact plates are subject to intense friction with the materials for a long time, resulting in extremely severe wear of the components. The average service life of the hammer head is only 500 to 800 hours. Frequent replacement not only increases maintenance costs but also prolongs equipment downtime. According to statistics, the cumulative downtime of such equipment due to component replacement each year can reach 80 to 120 hours, directly affecting the continuity of the production line. Meanwhile, the problem of high energy consumption caused by high-speed operation is prominent, with the power consumption per unit product being 15% to 25% higher than that of new equipment.
Double roll crusher
By using two large-diameter rollers rotating relatively, the material is crushed through extrusion and grinding actions. Its working principle determines that the equipment’s clamping capacity for materials is limited, and it is only suitable for fine crushing operations of brittle materials (the output particle size is usually between 3 and 10mm), and cannot meet the requirements of medium and coarse crushing. In addition, the toothed structure on the surface of the roller is prone to wear during long-term extrusion, especially when handling materials with high hardness. The wear rate of the toothed roller surface can reach 0.5-1mm per week, which not only affects the uniformity of the output particle size but also increases the frequency and cost of equipment maintenance.
The superiority of Mineral Sizer
Strong processing ability
Adopting the principle of double-roll high-pressure shearing and crushing, the Mineral Sizer single machine can process over 3,000 tons of ore per hour, which is 15 times that of traditional jaw/cone crushers. Through the modular roller shaft design, the equipment can achieve continuous and stable operation. Combined with the intelligent feeding control system, it can maintain an operation rate of over 95% even under high-load conditions, significantly enhancing the overall production efficiency of the mine and the concentrator.
It occupies a small space
The innovative compact roller structure design makes the equipment’s floor space only 1/5 of that of traditional crushers. The height direction adopts a low-position layout scheme, and the overall height of the machine does not exceed 8 meters, which is approximately 1/7 of that of a traditional gyratory crusher. This three-dimensional space optimization design not only saves over 30% of the factory building construction cost, but also facilitates seamless connection with belt conveyor systems and screening equipment, significantly enhancing the flexibility of the factory area layout.
Low degree of wear
The core crushing component adopts a replaceable tungsten-cobalt alloy gear sleeve and tungsten carbide gear tip combination. Through a unique inlaying installation process, only local vulnerable parts need to be replaced after wear, reducing the replacement cost by 80% compared with the traditional integral crushing roller. When the equipment is in operation, the intelligent monitoring system provides real-time feedback on tooth surface wear data. Combined with an AI prediction model, the maintenance cycle can be extended to three times that of traditional equipment, and the annual maintenance cost can be reduced by more than 60%.
Precise product control
By adjusting the speed difference and gap parameters of the roller shafts, Mineral Sizer can achieve precise particle size control ranging from 10 to 200mm, and the standard deviation of the finished product particle size distribution is reduced by 40% compared with traditional crushers. The special lamination crushing mechanism causes the material to break along the crystal cleavage plane. The proportion of cubic particles in the finished product exceeds 85%, and the generation rate of fine powder (-5mm) is controlled within 12%. This refined product quality control can significantly enhance the subsequent grinding efficiency and reduce the ball consumption cost by 15% to 20%.
The core advantages of Mineral sizer
Screening function
The main working components of Mineral sizer are two parallel installed crushing rollers. The center distance between the two crushing rollers is fixed. Each toothed roller is arranged with a certain number of crushing tooth sleeves or tooth plates along the axial direction, and the tooth shape structure is unique.
After the material falls between the two rollers of the crusher, it is immediately caught by the eagle-beak teeth or knife-shaped teeth plates on the rollers, and the shear force and tensile force applied to the material gradually increase. In fact, the structure of the crushing teeth is a rotating screen. Particles smaller than the discharge particle size can pass through directly without crushing, which improves the situation in traditional roller crushers where the material is crushed without control.
Reducing the increment of fine particles to the minimum also lowers energy consumption and reduces tooth wear. Due to the low rotational speed of this equipment and the above-mentioned characteristics, it has potential screening functions.
Tooth plate fixation
The tooth plates of other brands are fixed by bolt tension without a dovetail groove mechanism. As a result, the bolts are prone to greater force and are likely to break, further causing the tooth plates to fall off. Our mineral sizer uses a single-sided dovetail groove, complementing the bevel of the insert strip clamping block, and then installs the broken tooth plate onto the tooth plate fixing seat.
A surface-to-surface connection is formed, and the function of the bolt becomes to fix the insert strip clamping block, avoiding the problems of the fixed locking bolt breaking, the tooth plate falling off or being difficult to disassemble and replace. All the crushing tooth plates have moderate lengths and weights and are interchangeable, allowing for individual and independent replacement.
Dual overload protection
Fusible plugs of hydraulic couplings
The hydraulic coupling has an overload protection function. When the load is overloaded, the oil temperature inside the hydraulic coupling gradually rises. When the temperature reaches a certain level, the alloy of the fusible plug melts, and the oil in the oil cavity of the hydraulic coupling is sprayed out, causing the equipment to shut down for protection.
When the hydraulic coupling is overloaded or the oil temperature in the hydraulic coupling oil control rises, the fusible alloy melts and the oil flows out, which can achieve the function of overload protection and shutdown of the hydraulic coupling.
During normal operation, the possibility of fusible alloy being flung out from the plug body of the fusible plug when the load is not overloaded is eliminated, which improves the reliability of the fusible plug and avoids abnormal flying out caused by the fusible alloy not being melted during the normal operation of the hydraulic coupling, resulting in shutdown.
Self-aligning drum gear coupling
The self-aligning drum gear coupling has a self-aligning function and can effectively solve the problems of insufficient concentricity and errors. The tooth profile adopts a flanged design and the surface is treated with high-frequency quenching. It has an extremely strong ability to transmit torque and resist impact. The outer gear sleeve of the double-sided half coupling is designed with a shear pin group. When the crusher is stuck, it can effectively protect the drive unit.
Driving mode
The drive mode of other brands usually adopts the direct connection mode of motor and reducer, without a hydraulic coupling as a buffer, which has a huge impact on the power grid. There are also those that adopt the direct connection mode of motor and reducer + pulley + belt + toothed roller assembly, but belt transmission is not suitable for the toothed roller crusher to crush hard rock materials, as it is prone to slippage and damage. Our mineral sizer is equipped with an electric motor, a hydraulic coupling, a reducer, a self-aligning drum gear coupling and a gear roller assembly. The hydraulic coupling has a soft start function to buffer the impact on the power grid, and also features fusible plug and burst plug protection functions
Conclusion
Our mineral sizer redefines efficiency in mineral processing, combining cutting-edge shear technology with robust engineering to outperform traditional crushers in productivity, durability, and cost-effectiveness.
