Core Advantages of Double Roll Sand Making Machine
The double-roll sand making machine (double-roll sand making machine) demonstrates significant advantages in the field of sand and gravel processing thanks to its unique structural design and process characteristics. The following is a systematic summary of its core advantages in terms of efficiency, energy consumption, maintenance, and intelligence, combined with actual application scenarios to illustrate its value:
double-roll sand making machine
1、 High-efficiency crushing and precise particle size control
1. High crushing efficiency
Utilizing dual-roll synchronous compression crushing, materials undergo dual effects of shear force and compression force as they pass through the roll gap, achieving a high crushing ratio (up to 1:15) with an hourly output range of 200–400 tons.
Suitable for medium-hardness materials (e.g., limestone, river pebbles), processing speed is 30% faster than traditional jaw crushers.
2. Precise and Adjustable Particle Size
The roller gap (0.5-20 mm) can be adjusted via hydraulic or wedge mechanisms, enabling precise control of the output particle size within the range of 0.5-40 mm to meet various grading requirements.
The finished particles exhibit a cubic shape, with needle and flake content <5%, outperforming impact crushers.
2、Energy Efficiency, Low Consumption, and Intelligent Operation
1. Energy Efficiency Advantages
Compared to cone crushers, energy consumption is reduced by 20%-30%, with power consumption per ton ranging from 0.5-1.2 kW·h.
Optimized transmission systems (such as variable frequency motor drives) reduce impact current during no-load startup, achieving significant energy savings.
2. Intelligent control
Integrated PLC system supports automatic adjustment of the roller gap, fault diagnosis (such as overload alarms and blockage warnings).
Remote monitoring functionality enables real-time collection of production data, reducing the need for manual intervention.
3、Low Maintenance Costs and Long-Life Design
1. Wear-Resistant Roller Surface Technology
Roller liners are made of high-chromium alloy or tungsten carbide overlay, with a lifespan of 3-5 years (compared to 1 year for standard rollers), extending the replacement cycle by 2-3 times.
Modular roller shell design allows for localized wear repairs without replacing the entire unit.
2. Easy-to-maintain structure
The hydraulic gap adjustment system simplifies maintenance procedures, enabling a single operator to adjust the roller gap (taking less than 1 hour).
Sealed dust-proof plates reduce dust ingress into bearings, extending lubrication intervals to 200 hours.
4、 Enhanced environmental protection and safety
1. Low dust and noise
Closed crushing chamber + built-in dust-proof plates, dust emissions < 10 mg/m³, noise < 75 dB, compliant with environmental standards.
Wet material anti-adhesion design (e.g., scraper device) reduces the frequency of shutdowns for cleaning.
2. Safety Protection
Overload protection springs or hydraulic systems prevent foreign objects (such as metal pieces) from damaging the equipment, with a shutdown response time <0.5 seconds.
Hydraulic cover opening design for maintenance avoids the risk of manual entry into the crushing chamber.
5、 Wide Applicability and Cost-Effectiveness
1. Multi-scenario Adaptability
Suitable materials: river pebbles, limestone, steel slag, coal gangue, and other medium to low hardness minerals.
Application areas: construction aggregates, ceramic raw materials, coal beneficiation processes, recycled resource recovery, etc.
2. High Return on Investment
Initial costs are 25% lower than cone crushers, maintenance costs are reduced by 40%, and overall benefits are significant.
Modular design supports rapid installation, and no major infrastructure changes are required when retrofitting existing production lines.
6. Typical Application Cases
1. Sand and Gravel Plant Upgrade
A sand plant adopted the 2PG1200×1000 double-roll sand-making machine to crush river pebbles to 0-5 mm, achieving a production capacity of 200 tons per hour, with a particle size合格率improved to 95%.
2. Steel slag recycling
Processing steel plant steel slag (≤50 mm) to ≤3 mm for use as roadbed material, with a roll surface lifespan of 4 years and a 30% reduction in annual maintenance costs.
Summary
Double-roll sand-making machines offer core advantages in efficiency, energy savings, low maintenance, and environmental friendliness, making them particularly suitable for scenarios with high particle size precision requirements and harsh production environments. When selecting a model, key considerations include material hardness (≤160 MPa), moisture content (<10%), and output particle size requirements. Prioritize models equipped with intelligent control systems and wear-resistant roll surface technology to achieve long-term stable operation and cost optimization.
