Eliminating Iron Contamination: 120 T/H Potassium Feldspar Plant in India
How upgrading to 2PGY1200×1000 Hydraulic Roller Crusher secured zero-iron purity and boosted ball mill performance.
1. Client Background & Pain Points
Our client, a tier-one ceramic raw materials refinery located in Gujarat, India, supplies premium potassium feldspar powder to high-end porcelain tile factories. Their legacy fine-crushing circuit relied on dynamic impact hammer mills, which created severe operational bottlenecks:
The high-velocity impact of the hammers caused rapid wear, shedding magnetic and non-magnetic iron debris directly into the K-Feldspar, reducing the sintered whiteness.
Brittle feldspar generated over 28% useless powder under hammer impact, choking the fine screening system and creating heavy dust pollution.
2PGY1200×1000 On-Site Integration
2. Engineered Customized Solution
Our engineering team completely redesigned the secondary fine crushing circuit by replacing the impact mills with our 2PGY1200×1000 Heavy-Duty Hydraulic Double Roller Crusher.
The system configures low-speed (60-80 RPM) rollers made from specialized non-magnetic wear alloys. Operating with an optimized 4mm hydraulic discharge gap, the raw -80mm feldspar feeds steadily into the rollers, creating high-density laminar static compression that cracks the minerals cleanly without scraping steel elements.
3. Proven Transformation Data
| Performance Metrics | Legacy Impact Hammer Mill | 2PGY Hydraulic Roller Crusher | Net Improvement |
|---|---|---|---|
| Iron Contamination Rate | > 0.35% (High staining) | < 0.02% (Pure Glaze Grade) | 94.2% Reduction |
| Over-crushing Powder Fines | 28.5% waste slime | 8.2% uniform micro-cracks | 20.3% Material Saved |
| Ball Mill Throughput | 85 t/h (Dense particles) | 115 t/h (Prefractured cubic) | +35.2% Yield Boost |
| Wear Part Lifespan | ~ 15 to 20 Days (Hammers) | 8 to 10 Months (Alloy Shells) | 15X Lower Maintenance |
4. Client Verdict
“The 2PGY roller system completely turned our operations around. Not only did it eliminate the post-crush magnetic cleaning processes by preventing iron wear at the source, but the pre-fractured micro-cracks in the cubic feldspar feed also reduced our ball milling energy bills by 22%.”
— Production Director, Gujarat Mineral Minerals Corp.
Replicate This Success For Your Mineral Processing Line
Our engineering desk can simulate your raw potassium feldspar parameters to configure an optimized, iron-free crushing solution.
