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Applicable materials:River pebbles, calcite, quartz stone, marble, cobblestone, bentonite, iron ore, bluestone, mountain rock, water slag, limestone, weathered sand, diabase, granite, basalt, silicon carbide, emery, sintered bauxite, magnesia, etc.
The client, a major nickel producer operating an HPAL facility in Sulawesi, Indonesia, was expanding its processing capacity to meet growing demand from the electric vehicle battery supply chain. The HPAL process requires finely crushed, uniformly sized ore feed to maximize nickel and cobalt extraction in the autoclave. However, the project faced a critical bottleneck from the very beginning: the crushing circuit could not reliably process the ore.
red clay nickel ore
The red clay nickel ore at this site exhibited extreme handling difficulties:
Clay content of 35–40% — far beyond the design limits of conventional crushers
Moisture levels reaching 42% during the five-month rainy season
Extreme material stickiness — ore adhered to every surface it touched
Frequent hard saprolite cores embedded within the soft clay matrix
The original crushing circuit was configured with cone crushers for the secondary and tertiary stages.
The results were disastrous:
| Operational Issue | Impact |
|---|---|
| Crushing chamber clogging | Cone crushers blocked every 30–60 minutes during wet-season operation |
| Manual cavity clearing | Required 2–3 workers, 20–40 minutes per incident |
| Equipment availability | Dropped below 55% during the rainy season |
| Production shortfall | Plant throughput fell to 40% of design capacity |
| Maintenance burden | Bowl liners and mantle wear accelerated by abrasive clay slurry |
| Screen blinding | Vibrating screens required hourly cleaning |
Equipment Selection
After a thorough evaluation of alternative crushing technologies, the client selected Huashengming ‘s 2PGY1200×1000 Hydraulic Roll Crusher for both the secondary and tertiary crushing stages.
| Selection Criteria | Roll Crusher Performance | Cone Crusher (Previous) |
|---|---|---|
| Clay ore handling | No enclosed chamber; forced passage | Constant clogging |
| Wet-season operation | Moisture aids material flow | Moisture causes blockage |
| Product uniformity | Precisely controlled roll gap | Variable, inconsistent |
| Fines generation | <15% at -1mm | 25–35% at -1mm |
| Energy consumption | 0.5–0.7 kWh/t | 1.2–1.5 kWh/t |
| On-site maintainability | Roll hardfacing on-site | Liner replacement in workshop |
During the initial load testing, the following observations were recorded:
No material adhesion to roll surfaces, even with ore moisture at 40%
Automatic scrapers effectively removed the small amount of clay that initially adhered
Hydraulic gap adjustment allowed operators to fine-tune product size within minutes
Overload protection activated twice during testing when hard saprolite cores entered — each time the system released and reset automatically in under 3 seconds
Product size distribution immediately met the HPAL feed specification without circuit tuning
Double roll crusher 2PGY1200*1000
Right Technology for the Right Ore: The roll crusher’s compression-forced-passage principle was fundamentally compatible with the wet, sticky, clay-rich characteristics of laterite nickel ore.
System-Level Thinking: The solution was not just a crusher replacement — it was a complete circuit reconfiguration that optimized the entire crushing-to-leaching chain.
Proven in Extreme Conditions: Two full rainy seasons of operation have validated the technology’s reliability in the most challenging moisture conditions.
Rapid ROI: The total project payback period was under six months, driven primarily by increased nickel recovery and eliminated downtime.
Huashengming is a specialized manufacturer of crushing and screening equipment for the global mining industry. Our roll crusher series has been successfully deployed in nickel, gold, copper, lithium, and industrial mineral processing projects across Asia, Africa, Australia, and the Americas.
We specialize in solving difficult ore handling challenges — particularly wet, sticky, and clay-rich materials that defeat conventional crushing equipment.
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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