In the gold ore crushing process, the choice of roll crusher (especially full hydraulic or high pressure roller mill) has significant advantages, but also need to be combined with the characteristics of the ore and the production scale of a comprehensive assessment. The following is a systematic analysis of the core value, applicable scenarios, selection points and typical cases:
1. Core advantages of gold ore roller crusher
High Pressure Roll Mill
High-efficiency dissociation and recovery rate enhancement
Microcracking effect: High Pressure Roll Mill generates microcracks inside the ore through hydrostatic pressure extrusion, which enhances the efficiency of subsequent cyanide leaching, and the gold recovery rate can be increased by 3-5 percentage points (e.g., the case of Zhaoyuan gold mine in Shandong Province is from 88.6% → 93.2%).
Precise particle control: Hydraulic adjustment of roll spacing (0.1-40mm), stable discharge particle size of 1-10mm, avoiding over-crushing and reducing grinding energy consumption by 20%-30%.
Energy saving and economy
Optimisation of energy consumption: the unit power consumption is as low as 2.4kW-h/tonne, which is 25% energy-saving compared with the traditional three-stage crushing (jaw+cone crusher), and the annual electricity cost of large mines is over 18 million RMB.
Low maintenance cost: high chrome alloy/tungsten carbide roll surface life of more than 10,000 hours, annual maintenance costs down 45%, modular design to shorten downtime.
Strong adaptability
Complex ore processing: the double-roll structure can process clay-containing or high-moisture ores (water content ≤15%), and the anti-clogging effect is better than that of cone breakers.
Low-grade ore development: the economic boundary grade is reduced from 3.0g/t to 2.5g/t, activating hard-to-mining resources.
Environmental Protection and Intelligence
Dual control of dust and noise: sealed structure + dust removal system, dust concentration <10mg/m³, noise <85dB.
AI dynamic optimization: PLC system real-time adjustment of roller pressure and speed, improving dissociation degree by 15%.
2. Scale matching programme
Gold Ore Crushing Site
Small mine (<500,000 tonnes/year): Jaw Crusher (coarse crushing) + Hydraulic Roller Crusher (fine crushing), e.g. PE600×900 + 2PG750×500 combination, payback period <2 years.
Large-scale mines (>1 million tonnes/year): gyratory breaker (coarse crushing) + high-pressure roller mill (fine crushing) + ball mill, e.g., HPT500S system, with 18.5% reduction in energy consumption per unit.
3. Potential limitations and coping strategies
Limitation of processing capacity
The upper limit of the processing capacity of a large high-pressure roller mill is about 850 tonnes/hour. Super-large-scale projects require multiple parallel units or cone crushers.
Countermeasures: rotary breaker (coarse crushing) → high-pressure roller mill (fine crushing) → cone breaker (closed-circuit screening), to ensure that the capacity convergence.
Wear and tear of super-hard ores
Extremely hard ores with compressive strength >250MPa (e.g. containing diamond inclusions) may accelerate the wear of roll surface.
Countermeasure: Use tungsten carbide composite roller faces (life expectancy extended to 30,000 hours), or front-loaded jaw breakers to reduce the feed size.
High initial investment
The price of large high-pressure roller mill is 500,000-800,000 RMB, and the intelligent hydraulic model is 20%-30% higher than the basic model.
Countermeasure: Prefer localised service provider (e.g. Huashengming Heavy Industry) to reduce the purchase and maintenance cost.
Roll crusher has excellent performance in gold ore crushing, especially suitable for low-grade ore development, clay-bearing ores and energy-saving and consumption reduction demand scenarios:
Preferred Scenario:
Medium and low hardness gold ore (compressive strength ≤ 200MPa), clay-containing/wet ore, decentralised mining area;
Projects pursuing high recovery rate (microcracking effect) or low grinding energy consumption.
Choose the scenario with caution:
Ultra-hard ore (>250MPa) requires enhanced wear-resistant configuration;
Super-large-scale projects (>1000tph) are recommended to be matched with rotary breakers or cone breakers.
Key to selection: Combined with the silica content of the ore, production scale and the need for intelligence, the high-pressure roller mill is preferred for large-scale projects to release the potential of microcracking, while the hydraulic roller breaker is preferred for small and medium-sized mines to balance cost and efficiency.
