To efficiently and accurately crush and splitting a 100mm hard rock sample to a final product size of 2mm. Due to the large feed size of the sample, single-stage crushing is difficult to meet customer requirements. Therefore, we have tailored a joint process solution of “jaw crusher + double-roll crushing and splitting unit” for them. This equipment mainly consists of an automatic loading hopper, jaw crusher, double-roll crusher, electric splitting machine, and an overall steel structure frame. Its core features are a small footprint and high automation level. The design is referenced in the following image:
Rough crushing: jaw crusher efficient pre-processing
The ore sample is first fed into a jaw crusher. This equipment uses the principle of curved squeezing crushing, relying on two high-wear-resistant jaw plates to forcefully crush large pieces of material. At this stage, the 100mm raw ore is quickly and stably crushed to a particle size of about 10mm. The jaw crusher has a large crushing ratio and high compressive strength, providing a qualified material source for subsequent fine crushing.
Technical Parameters of Jaw Crusher:
Feed Opening Size (mm): 125 × 150
Maximum Feed Size (mm): ≤ 100
Discharge Size (mm): 6 – 38 (Adjustable)
Crushed Ore < 4mm: 60 – 70%
Jaw Plates Material: Manganese Steel
Spindle Speed (r/min): 350
Capacity (kg/h): 500 – 3000
Capacity (Discharge Size < 4mm): 50 – 500 kg/h
Motor Power (kW): 4
Power Supply: Three-phase, 380V, 50Hz
Overall Dimensions (mm): 1150 × 680 × 1100
Equipment Weight (kg): 515
Material transport: Smooth transition and connection
The 10mm material discharged from the jaw crusher falls automatically into the second-stage double-roll crusher due to gravity. It also ensures perfect capacity matching between front-end and back-end equipment, eliminating material blockage.
Secondary crushing and splitting: Precision shaping with dual-roll crusher
After the material enters the double-roll crushing and splitting machine, it enters the critical crushing and sizing stage. The equipment adopts the double-roll extrusion crushing principle to further crush the 10mm material to the target particle size. At the same time, the built-in splitting system of the equipment performs horizontal reciprocating motion to regularly cut and divide the material. By infinitely adjusting the sizing ratio, the final precise output is a 2mm mineral sample.
Technical Parameters of Double Roll Crusher:
Roller Size: D250 × 150
Feed Opening Size (mm): 150 × 13
Roller Material: Manganese Steel
Max. Feed Size (mm): ≤ 13
Discharge Size (mm): 1 – 3 (Adjustable)
Capacity (kg/h): 600
Roller Speed (r/min): 400
Motor Power (kW): 3
Power Supply: Three-phase, 380V, 3kW
Reduction Ratio: 1/2, 1/4, 1/8 (Adjustable)
Working Mode: Primary crushing, primary splitting
Splitting Motor Power (kW): 0.55
Equipment Weight (kg): 300
In the process of crushing and splitting large ore samples, the advantages of using our jaw crusher + double-roll crushing and sieving unit:
- Precise control and strong sample representativeness: The jaw crusher is responsible for primary crushing, while the double-roll crusher handles “fine crushing+ splitting.” The material produced by the double-roll extrusion is mostly in regular sheet form, and with thematch of a scientific divider, it ensures that the final 2mm sample has extremely high representativeness in terms of chemical composition and physical properties.
- High automation, reducing manual intervention: From 100mm feed to 2mm output, no manual screening required, reducing the workload of lab personnel and improving per capita processing efficiency.
- High equipment adaptability, stable operation: The combination of jaw and double-roll can effectively handle brittle and medium-hard materials, and the double-roll equipment is less prone to particle adhesion when the material moisture content is controllable, ensuring the continuous and stable operation of the production line.
Refer to the production photos and loading videos of this crushing and split machine group.
The video shows the loading process of our two-stage crushing and automatic splitting integrated equipment. This equipment consists of an automatic loading hopper, a jaw crusher, a double-roll crusher, an electric splitter, and an overall steel structure frame. Its key feature is a small footprint and high level of automation. It can efficiently and precisely crush and split a 100mm hard rock sample into a finished particle size of 2mm.
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