How a 120 T/H Indian Plant Cut Iron Contamination by 94% and Energy Bills by 22%

Applicable materials:River pebble, calcite, quartzite, marble, pebble, bentonite, iron ore, bluestone, mountain stone, water slag, limestone, weathered sand, diabase, granite, basalt and so on

  • Feed size:25-100mm
  • Productive capacity:5-450t/h

Key Equipment

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Global Success Story

Eliminating Iron Contamination: 120 T/H Potassium Feldspar Plant in India

How upgrading to a 2PGY1200×1000 Hydraulic Roller Crusher secured zero-iron purity and boosted downstream ball mill performance.

1. Client Background & Operational Bottlenecks

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 secondary fine-crushing circuit relied on high-velocity impact hammer mills, which created severe quality and financial crises:

High Iron Rejection Rates:
The high-speed striking action of the hammers caused rapid abrasive metal wear, shedding fine magnetic and non-magnetic iron debris directly into the K-Feldspar matrices and destroying the sintered whiteness of the tiles.
Excessive Mud Slime Fines:
The brittle feldspar generated over 28% useless fine powder sludge under repetitive impacts, choking the screening structures and creating heavy dust hazards inside the plant.
2PGY1200×1000 On-Site Integration

2PGY1200×1000 On-Site Integration

2. Engineered Customized Solution

Our material engineers completely overhauled the secondary milling loop by replacing the failing impact crushers with our heavy-duty 2PGY1200×1000 Hydraulic Double Roller Crusher.

The customized configuration features low-speed (60-80 RPM) rollers cast from specialized non-magnetic wear alloys. Operating with an optimized 4mm hydraulic discharge setting, the raw -80mm feldspar runs steadily into the pinch zone, triggering dense inter-particle static compression that fractures the minerals along natural crystal boundaries 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 Slime 28.5% waste fines 8.2% uniform products 20.3% Recovery Saved
Ball Mill Throughput 85 t/h (Dense chunks) 115 t/h (Pre-fractured micro) +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 downstream ball milling energy bills by 22%.”

— Production Director, Gujarat Material Processing 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 plant solution.

suitable for more than 200 types hard materials
  • Small-Scale Gold Ore Crushing Line
  • Granite sand making
  • Molybdenum ore beneficiation
  • Limestone sand making

Gongyi Huashengming Heavy Machinery Factory

Gongyi Huashengming Heavy Industry Machinery Factory is a production of crushing and screening equipment, production, sales as one of the large machinery intelligent manufacturing enterprises. Company headquarters is located in the Central Plains of the pearl Gongyi City, the main roller crusher equipment, mobile sand making equipment, screening equipment and construction waste treatment equipment series products, our company’s production site thousands of thousands, all over the provinces and cities. Over the years we have been consistent, honest service to every customer. We sincerely look forward to cooperating with you.

 

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