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Global Project Case Study

120-200 t/h Hard Rock Crushing Plant Integration

How APEX advanced electromechanical-hydraulic double roller systems optimized high-grade construction aggregate yield and minimized operational overhead.

1. Project Background & Challenges

Large-scale aggregate and infrastructure projects worldwide demand strict control over flake-like particle fractions and heavy power consumption. Traditional impact or cone crushers often struggle when handling diverse materials, generating excessive useless fines, leading to severe component wear, and failing under unexpected tramp iron events.

To resolve these operational bottlenecks, this industrial project deployed the APEX Large Hydraulic Double Roller Crusher circuit. Designed for intelligent, high-tonnage medium and fine material reduction, the system combines robust raw material pinch forces with responsive smart control loops, achieving an eco-friendly and highly cost-efficient production flow.

Large Double Roller Crusher Operating On-Site

Large Double Roller Crusher Operating On-Site

2. Engineered Solutions Implemented

• Instantaneous Tramp Iron ClearanceThe heavy-duty movable roller frame incorporates a hydraulic pressure relief valve. If steel shards or uncrushable hazards enter the chamber, the rolls instantly back away to drop the tramp object and self-reset without pausing production lines.
• High-Pressure Compression MechanicsBy moving away from dynamic high-speed impact and adopting low-RPM static extrusion, the system slashes operational energy consumption by up to 30%, significantly scaling down plant power costs.
• Premium Alloy Wear ResistanceOur proprietary high-chromium manganese roller composition easily withstands harsh mineral abrasiveness, extending normal wear component lifespans by 3 to 5 times over traditional cast irons.
• Real-Time Grading & Size CustomizationOperators can adjust physical roller gap configurations on-the-fly via a centralized automated PLC unit. This directly outputs premium, cubic-shaped products that meet strict global sand and aggregate standards.
• Eco-Safe Structural Environmental EnclosureThe processing line is wrapped in heavy, fully enclosed structural steel covers. Together with targeted dust-extraction ports, it naturally isolates low-frequency mechanical noise and fine fugitive particulates.

3. Operational Process Workflow

To maintain high production continuity and narrow particle size margins, the plant relies on a precise 4-stage laminar static compression cycle:

1

Controlled Feeding: Raw materials slide continuously from upper surge bins into the vertical center of the crushing chamber.

2

Friction-Driven Intake: The heavy counter-rotating surfaces grip the rock matrix, guiding it seamlessly down into the main high-pressure pinch zone.

3

Static-Extrusion Fracturing: Materials are compressed beyond their specific elastic limits, cleanly cracking raw feed particles down along natural intergranular boundaries.

4

Uniform Discharge: Fractured minerals cleanly clear the pre-set gap, exiting onto the belt conveyors with zero chamber clogging.

4. Plant Configuration Matrix

Model Reference Roll Diam. (mm) Roll Width (mm) Max Feed Size Hourly Output Drive Power
APEX 2PGY750×500 φ750 500 ≤40 mm 20 – 30 t/h 2×(22-30) kw
APEX 2PGY800×600 φ800 600 ≤40 mm 30 – 40 t/h 2×(30-37) kw
APEX 2PGY800×800 φ800 800 ≤40 mm 40 – 50 t/h 2×(37-45) kw
APEX 2PGY1000×800 φ1000 800 ≤40 mm 50 – 80 t/h 2×(45-55) kw
APEX 2PGY1000×1000 φ1000 1000 ≤60 mm 80 – 100 t/h 2×(75-90) kw
APEX 2PGY1200×1000 φ1200 1000 ≤80 mm 100 – 120 t/h 2×(75-132) kw
APEX 2PGY1500×1200 φ1500 1200 ≤120 mm 150 – 200 t/h 2×(132-160) kw
APEX 2PGY1800×1000 φ1800 1000 ≤100 mm 250 – 300 t/h 2×(250-315) kw
APEX 2PGY2000×1200 φ2000 1200 ≤120 mm 300 – 400 t/h 2×(315-355) kw
Hydraulic Double Roller Crusher

Hydraulic Station & PLC Control Module setup

5. Proven Field Applications

• Hard Rock & Metal Ore Milling: Delivers heavy volume pre-grinding crushing for iron ore, copper lode, gold vein ores, limestone, and dolomite, drastically cutting downstream ball mill cycles.

• High-Specification Infrastructure Supply: Processes highly cubic manufactured sand and gravel chips tailored for deep-water dams, railway ballast, and expressway concrete Aggregate batches.

• Commercial Cement & Gangue Grinding: Manages dry cement clinker processing, coal gangue cleaning, and gypsum milling rows across continuous building material loops.

• Smelting & Coking Operations: Controls uniform fine reduction of coking coal fractions alongside abrasive industrial metallurgical Steel Slag, slag run, and active quicklime.

• Eco-Safe Urban Reclamation: Fractures demolition concrete beams, cured masonry bricks, and slag-heavy industrial Mineral tailings to feed recycling loops with high safety margins.

• Premium Ceramic & Silicate Blends: Processes high-purity industrial Quartz sand, raw potash feldspar ore, and fine refractory compounds with tight grain envelope control.

Request an Engineering Site Consultation

Our bulk material processing experts can calculate roller wear lifespans and draft custom layout blueprints according to your hardness metrics and target production rates.

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