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Applicable materials:Vanadium-Titanium Magnetite, Iron Ore, river pebble, Calcite, quartzite, marble, cobble, bentonite, iron ore, bluestone, mountain stone, water slag, limestone, weathered sand, Diabase, granite, basalt
Application scope:Highway, railway, high-rise buildings, municipal, hydropower dam construction, concrete mixing station, sand and stone field, etc.
Iron ore, known for its extreme hardness and abrasiveness, poses a significant challenge to traditional crushing equipment. In this case, we demonstrate how the HSM Double Roller Crusher provides a high-performance solution for a large-scale magnetite processing plant, focusing on the core strategy of “More Crushing, Less Grinding.”
Sand Raw Materials
Iron ore acts like sandpaper on machinery. This case features our high-chromium alloy roller skins. After 18 months of continuous operation at this site, the roller surface showed minimal wear, significantly reducing the downtime compared to the hammer crushers previously used by the client.
By crushing the iron ore to a stable 8mm size before it enters the ball mill, the plant reported a 30% increase in total production capacity. The ball mill’s energy consumption per ton was reduced by 25%, achieving significant operational cost savings.
In iron ore mining, tramp iron (like broken shovel teeth) can be a disaster. Our hydraulic system senses uncrushable objects and automatically opens the rollers to let them pass, resetting in seconds without stopping the flow. This ensures 24/7 stable production.
“Since switching to the HSM Double Roller Crusher, our maintenance costs have dropped by 40%. The output particle shape is excellent, which has greatly improved the efficiency of our subsequent magnetic separation process.”
Whether you are dealing with hematite, magnetite, or tailings recovery, HSM provides customized roller surface solutions to match your specific mineral characteristics.
Working principle
Driven by two independent motors, the counter-rotating rollers of the crusher apply intense compression and shearing forces to pulverize materials. Once the feed enters the crushing chamber, it is processed between the rollers and discharged via gravity. To protect the equipment, a hydraulic or spring-loaded safety system allows the rollers to automatically retreat when encountering uncrushable objects. Users can precisely manage the final output granularity by adjusting the hydraulic pressure or spring tension to control the roller gap.
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