Limestone Crusher Machine

Our Limestone Crusher Machine adopts the advanced concept of classification crushing. It precisely processes the materials through two rotating rollers that face each other.
When the limestone falls into the crushing chamber, not all the materials undergo intense crushing; the materials smaller than the target size can directly pass through the gap between the rollers, while only the oversized chunks are bitten by the special tooth shape.
This selective crushing mechanism significantly reduces unnecessary energy consumption. Compared to traditional crushing equipment, it saves over 25% of energy. At the same time, it effectively controls the over-crushing phenomenon and ensures that the fine powder content in the finished product is at a low level in the industry.

 

 

 

(1) Jaw Crusher

 

• 
• ● Working Principle

The core of crushing in a jaw crusher is the "compression effect". Its structure consists of four key components: fixed jaw, movable jaw, thrust plate, and eccentric shaft:

• ① The movable jaw is suspended on the eccentric shaft, and its bottom is supported by the thrust plate against the rear wall of the frame;
• ② When the eccentric shaft rotates, the movable jaw will simultaneously undergo reciprocating motion and up-down movement, causing the space between the movable jaw and the fixed jaw to constantly change;
• ③ After the material enters between the two jaws, it is continuously compressed until it is crushed, and the crushed material is freely discharged from the lower end of the equipment.

 

• ● Application Pain Points

This compression crushing method has obvious flaws: Regardless of whether the material has reached the target particle size of 40-80mm or not, it will be repeatedly compressed. During the compression process, multiple collisions and friction between the jaw plates and the materials, as well as between the materials themselves, are prone to cause over-crushing.

According to production practice statistics, when a jaw crusher is used to crush limestone, the yield of qualified particle size of 40-80mm is only about 30%, A large amount of materials are crushed to the fine particle size of below 40mm. These fine particle materials not only cannot meet the requirements for lime production, but also cause resource waste and increase the cost of subsequent tailings treatment. Therefore, the jaw crusher is only suitable for coarse crushing and cannot be used as the final particle size control equipment.

 

 

(2) Impact Crusher

 

• ● Working Principle

After the material enters the feeding port from above the equipment, it will be subjected to multiple effects from the high-speed rotating hammer heads:

• ① Firstly, it is directly struck by the hammer heads, gaining a huge amount of kinetic energy;
• ② Subsequently, there are secondary impacts and grinding between the hammer heads and the liners, as well as between the materials;
• ③ Materials smaller than the sieve plate's sieve hole size pass through the sieve plate and are discharged, while materials larger than the sieve hole remain on the sieve plate and continue to be struck and ground by the hammer heads until they meet the particle size requirements.

 

• ● Application Pain Points

The weaknesses of impact crushers are concentrated in two core aspects:

• ① Over-crushing Issue Is Prominent: The rotor speed of these crushers usually ranges from 300 to 3000 rpm, the high-speed rotating hammers will exert intense impact on the materials. According to the theory of rock fracture mechanics, high external force loading will cause rapid and disorderly merging of internal defects and cracks in the materials, resulting in a significant increase in the proportion of fine particle materials after crushing, the yield of qualified particle sizes of 40-80mm is similar to that of jaw crushers, unable to meet the requirements for fine processing;
• ② Low Processing Capacity: Due to the limitations of the equipment structure, the materials stay on the screen plate for a long time, and the discharge speed is slow. For large limestone mines with an annual output of over 1 million tons, the capacity of impact crushers simply cannot match, and they can only be used in small-scale production lines with low load.

 

 

 

 

Compared to traditional equipment, the Limestone Crusher Machine 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 Limestone Crusher Machine 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 Limestone Crusher Machine is divided into three stages: "initial screening - compound crushing - secondary screening", which enables precise control of the particle size of the materials:

 

 Initial Screening

After the raw materials enter the equipment, they first undergo initial screening by the crushing teeth. Materials that meet the target particle size of 40-80mm will be directly discharged from the space enclosed between the crushing teeth, without participating in the subsequent crushing process. This reduces over-crushing at the source.

 Composite Crushing

For materials exceeding the 40-80mm size requirement, the composite crushing stage will be activated. Under the action of two sets of interlaced crushing teeth, the materials will simultaneously be subjected to various forces such as shearing, stretching, bending, piercing, breaking, splitting, etc. These forces work together to efficiently crush large pieces of materials to the target size, and the crushing process is more uniform, reducing the generation of fine particles.

 Secondary Screening

If some materials fail to reach the target particle size after one stage of crushing, they will be flipped to a new position under the drive of the crushing teeth and enter the working area of the next set of crushing teeth, repeating the crushing process. This continues until all materials meet the 40-80mm particle size requirement, and then they will be discharged from the equipment to ensure the full compliance of the crushed materials.

 

 

 

 

 

 

 

Toothed roller can be divided into Primary Limestone Crusher Machine Toothed Roller and Secondary Limestone Crusher Machine Toothed Roller. Easy installation and disassembly of the Limestone Crusher Machine 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 Limestone Crusher Machine 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 Limestone Crusher Machine 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.

 

 

 

 

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