Limestone Crusher Cement Plant

In the cement production process, the control of limestone particle size is a crucial factor determining the quality of raw materials and the efficiency of calcination. The ideal grinding particle size not only significantly reduces the power consumption of grinding, but also enhances the thermal stability of the kiln system.
However, many cement plants are facing a serious challenge: Traditional crushing equipment, while striving for high production, often leads to a severe "over-crushing" phenomenon, resulting in low yields of high-value ideal block materials (such as 40-80mm), while the proportion of low-value fine powder is too high. This not only causes a huge waste of resources, but also directly erodes the profit margin of the enterprise and brings environmental pressure from the accumulation of tailings.
Our Cement Limestone Crusher , with precise gap control and unique crushing principle, can suppress over-crushing and increase the yield of ideal particle size, helping cement plants solve problems and improve efficiency.

 

 

 

(1) Jaw Crusher

The jaw crusher operates based on the "compression principle": The eccentric shaft drives the moving jaw to perform a reciprocating and combined up-and-down motion, causing the space between the moving jaw and the fixed jaw to continuously change. After the material enters, it is repeatedly compressed until it is crushed, and then it is discharged from the lower end.
However, this crushing method has obvious limitations - regardless of whether the material has reached the target particle size of 40-80mm, it will continue to be compressed. The multiple collisions and friction between the jaw plate and the material, as well as the material, are prone to cause over-crushing.
According to production practice, when crushing limestone, the yield of qualified particles within the 40-80mm range is only about 30%. A large amount of material is crushed to the fine particle size of 40mm or below, which not only fails to meet the requirements for the production of quicklime, but also leads to resource waste and an increase in tailings treatment costs. Therefore, it is only suitable for coarse crushing and cannot be used as the final particle size control equipment.

 

 

(2) Impact Crusher

The crushing logic of impact crushers is based on high-speed impact: After the materials enter the feed port, they are first directly struck by the high-speed rotating (300 - 3000 r/min) hammer heads, and then undergo secondary impact and grinding between the hammer heads, the liners, and the materials. Materials smaller than the sieve holes are discharged, while larger materials are continuously crushed to a qualified size. However, this equipment has obvious shortcomings:
Firstly, there is a prominent problem of over-crushing. The high-speed impact causes disorderly diffusion of internal cracks in the materials, resulting in a low yield of qualified particles of 40 - 80 mm, which is difficult to meet the requirements for fine processing;
Secondly, the production capacity is insufficient. The materials stay on the sieve plate for a long time and the discharge is slow, which cannot be adapted to large limestone mines with an annual output of over 1 million tons. It is only suitable for small-scale production lines with low load.

 

 

 

 

 

Compared to traditional equipment, the Cement Limestone Crusher has completely revolutionized the crushing mechanism - instead of relying on a single force such as "compression" or "impact", it adopts a combined crushing method of "shear + stretching". This crushing method can better match the physical properties of limestone, reducing excessive damage to the materials during the crushing process.

 

The Cement Limestone Crusher Has Three Core Features:

● High Crushing Strength: It can meet the crushing requirements of limestone (with an approximate compressive strength of 130 MPa), even when the material contains a small amount of hard impurities, it can still be crushed stably;

● Low Rotational Speed + Special Tooth Shape: The rotational speed of the crushing rollers is only a few revolutions per minute, combined with the specially designed tooth shape, it significantly reduces the occurrence of over-crushing and oversized materials;

● Wide Application Range: Besides limestone mines, it can also be applied in coal mines, power plants, metallurgy, chemical industries, etc., for the coarse and medium crushing operations of various brittle and blocky materials.

 

 

 

 

The crushing process of the Cement Limestone Crusher is divided into three stages: "initial screening - compound crushing - secondary screening", which enables precise control of the particle size of the materials:

 

Automatic Diversion and Instant Discharge

The crushing tooth structure acts as a rotating screen, allowing particles smaller than the discharge size to pass through directly without further crushing. This improves upon the uncontrolled, indiscriminate crushing of materials in traditional roller crushers, minimizing the increase in fine particles. This eliminates over-crushing at its source.

 Forced Feeding and High-Efficiency Processing

The crushing teeth employ a special helical tooth arrangement, determined by the on-site feed conditions. It features axial feeding, strong biting ability, and improved crushing efficiency. This effectively prevents the adhesion and blockage of sticky materials, ensuring the equipment's high processing capacity.

 Progressive Crushing

After the material falls between the crusher's double rollers, it is gripped by the beak-shaped or knife-shaped teeth on the rollers, with the shearing and tensile forces gradually increasing. Material exceeding the specified size is precisely subjected to shearing, tensile, and splitting forces between the staggered toothed rollers until it meets the requirements and is discharged. The entire process is gentle yet efficient, maximizing the preservation of the integrity of high-value materials.

 

 

 

 

 

 

 

 

Toothed roller can be divided into Primary Cement Limestone Crusher Toothed Roller and Secondary Cement Limestone Crusher Toothed Roller. Easy installation and disassembly of the Cement Limestone Crusher tooth head, which can significantly reduce the maintenance time and lower the maintenance cost.

 

The feeding granularity of primary sizers is less than or equal to 1500mm and the discharging granularity is less than 300mm. The arrangement of crushing tooth shapes and tooth shapes are arranged by special spiral tooth shapes. The crushing teeth are cast from abrasion resistant and impact resistant alloy steel. Primary Sizer toothed roller has a unique and novel tooth design structure with deep spiral distribution for high productivity. The passing cavities are formed between the two toothed rollers and the side plate body for screening and crushing materials respectively.

 

The Feeding size of Secondary sizer less than or equal to 300 mm (a small amount of 400mm is allowed), and the discharging granularity is less than 50mm. The connection form of the teeth plate adopts a single dovetail groove, which is complementary to the bevel of the insert clamping block, and then the crushing tooth plate is installed on the fixing seat of the teeth plate, formed a surface to surface connection, which is tightened and pressed by high-strength bolts. The function of the bolt becomes a fixed insert clamping block, avoiding the problem of the fixed lock bolt breaking, teeth plate falling off or difficult to disassemble and replace.

 

 

 

 

 

 

 

 

 

 

 

Primary Cement Limestone Crusher s Technical Specifications
Model	2PLF800	2PLF1000	2PLF1200	2PLF1500
Teeth Roller Dia (mm)	800	1000	1200	1400
Roll length (mm)	1500-2500	1500-3000	1500-3000	2000-3500
Max feed size (mm)	800	1000	1200	1500
Output size (mm)	≤300	≤300	≤300	≤300
Capacity (t/h)	≤2000	≤3500	≤6000	≤10000

 

Secondary Cement Limestone Crusher s Technical Specifications
Model	2PLS600	2PLS800	2PLS1000	2PLS1200
Teeth Roller Dia ( mm )	600	800	1000	1200
Roll length(mm)	1000-2500	1500-3000	2000-3500	2000-4000
Max feed size (mm)	200	300	350	400
Output size (mm)	50-80	50-100	50-120	50-140
Capacity ( t/h )	250-800	500-2000	600-3000	800-4000

 

1. Which material to be crushed:______
2. Handling capacity:______t/h.
3. Bulk material density: ______t/m3
4. The material compressive strength:______Mpa
5. The material HGI (hardgrove grindability index) range:
6. Material particle distribution percentage?
7. Max. grain size of the feeding material: ______mm
8. What is the grain size of the finished product after crushing?
9. What equipment is used to feed the material into the sizer?
10. What equipment is used to discharge the material from the sizer?
11. As we know,the sizer should form a system with other equipment, do you have preliminary design or hand-drawn sketch? If have, please send it to our engineer for reference.

 

 

 

 

Hot Tags: limestone crusher cement plant, China limestone crusher cement plant suppliers, manufacturers, Coal Secondary Sizer, Double Teeth Roll Crusher, Limestone Crushing Plant, High Capacity Mineral Sizer, Limestone Crusher Machine, Primary Sizer