Limestone Crusher

Limestone, as the core raw material for the production of chemical products such as quicklime and construction aggregates, has a very strong correlation between its product value and the particle size after crushing. The industry generally clearly requires that the raw materials should be precisely crushed to the ideal range of 40-80mm:

● If the particle size is too small, it will cause the "overburning" problem during the subsequent calcination process, directly reducing the product activity;

● If the particle size is too large, it is prone to the core hazard of "not being fully burned", resulting in resource waste and production capacity loss.

However, the jaw crushers and impact crushers relied on in traditional production have been unable to meet the current industry's dual core demands for precise particle size control and large-scale efficient production.

Therefore, equipment upgrading has become a crucial breakthrough point for enhancing production efficiency. And our Limestone Crusher is the preferred solution specifically designed to address the pain points in this industry.

 

 

 

(1) Jaw Crusher

• The jaw crusher has made significant contributions in the coarse crushing field due to its sturdy structure and powerful crushing force.
  Its working principle is to crush materials through the periodic squeezing of the moving jaw and the fixed jaw. However, this "unselective" squeezing method is the fundamental drawback when it is applied to the secondary or tertiary crushing of limestone in cement plants. The materials are repeatedly squeezed in the crushing chamber, regardless of whether their particle size has reached the standard or not, and they are difficult to avoid being overly crushed into useless fine powder.
  Practical data show that when the required finished particle size is 40-80mm, the qualified block rate of the jaw crusher usually only remains at around 30%. A large amount of stone is excessively crushed into useless fine powder, resulting in a significant reduction in economic benefits. Therefore, it is more suitable as a primary crushing equipment for handling large blocks of minerals.

 

 

(2) Impact Crusher

The impact crusher uses the high-speed rotating hammers to subject the materials to intense impacts, theoretically achieving better particle shapes. However, its high rotational speed (usually ranging from several hundred to three thousand revolutions per minute) also poses potential risks.
According to the theory of rock fracture mechanics, an excessively high loading rate of external force will cause the internal cracks in the rock to expand disorderly and in large quantities, thereby exacerbating the over-crushing phenomenon.
In addition, the discharge port of the impact crusher is prone to clogging, limiting its processing capacity and making it difficult to meet the large-scale, continuous production requirements of large cement plants. Its blockage rate is similar to that of the jaw crusher, and it also fails to meet the high-yield requirements of cement plants for specific particle size materials.

 

 

 

 

 

The Limestone Crusher represents a completely new philosophy of crushing. It is fundamentally different from traditional toothed roller crushers that rely on impact and compression to break down materials. Instead, it uses a combination of shearing and stretching to achieve the crushing of materials. Due to the use of low rotational speed and special tooth shapes, there is less over-crushing and oversize particle formation. This equipment is suitable for the coarse and medium crushing of brittle blocky materials in industries such as coal, power, mining, metallurgy, and chemical engineering.

 

The 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 Limestone Crusher 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 Toothed Roller and Secondary Limestone Crusher Toothed Roller. Easy installation and disassembly of the 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 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 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.

 

 

 

 

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