In the production chains of the chemical, construction and cement industries, limestone is an indispensable core raw material - in the chemical sector, it is used for preparing lime; in cement production, it is used for processing raw materials; in the construction industry, it is used for producing aggregates. All of these require strict requirements for the crushing particle size. The crushing effect in this stage directly determines the quality and efficiency of the subsequent production. The emergence of the Limestone Crusher has provided a new path for limestone mines and related enterprises to solve the traditional problems of "over-crushing and low production capacity" and achieve efficient production.

Traditional Crushing Equipment

(1) Jaw Crusher

In the limestone production line, the jaw crusher operates based on the core principle of compression crushing. It uses the eccentric shaft to drive the moving jaw to perform reciprocating and combined up-down movements, causing the space between the moving jaw and the fixed jaw to constantly change. The limestone entering the machine is continuously compressed until it breaks and then naturally discharged. However, it has obvious shortcomings. Not only does it cause severe over-crushing due to repeated compression, resulting in a qualified particle size of 40-80mm with a yield of only about 30%, but it is also prone to produce needle-like and flake-like materials. Moreover, it is only suitable for coarse crushing, has high energy consumption, and the jaw plates wear out quickly, which also significantly increases the maintenance cost.

(2) Impact Crusher

The impact crusher in limestone production operates based on the principle of impact crushing. After limestone is impacted by the high-speed rotating hammers, it undergoes multiple impacts and grinding between the hammers, the liners, and the materials. The qualified materials are then discharged through the discharge port. The disadvantages of this equipment are quite prominent. The high-speed impact can easily cause severe over-crushing, and the amount of dust is also large; it has poor adaptability to wet and sticky limestone, and is prone to clogging and shutdown; the wear-resistant parts such as the hammers and the counter-impact plates wear out quickly and need frequent replacement; at the same time, the materials stay in the crushing chamber for a long time and the discharging is slow, making it difficult to match the large-scale production requirements of large mines.

Why Use Limestone Crusher Instead Of Traditional Equipment

Cement Limestone Crusher At the Limestone Crushing Plant, the Limestone Crusher, with its advanced crushing principle, strong adaptability, and economic efficiency, has become the preferred alternative to traditional crushing equipment such as jaw, cone, and impact crushers.

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 core crushing structure of the Limestone Crusher consists of two parallelly arranged and synchronously rotating disc rollers. The surface of the disc rollers is equipped with alloy crushing teeth that can be replaced according to the characteristics of the materials and the crushing requirements. The tooth shape and pitch have been precisely designed to adapt to the crushing of minerals of different hardness.

During the feeding process, the most suitable method is to use a apron feeder or a dedicated screening equipment. These devices can strictly control the material conveying rate and evenly distribute the crushed minerals over the entire width of the two disc rollers, avoiding overloading of individual disc rollers or accumulation of materials.

When the minerals enter the gap between the two disc rollers, they are first firmly held by the leading surface of the relative rotor teeth. The concentrated load applied by the rotor teeth acts on the minerals, causing stress concentration within the minerals and generating fractures along their natural texture, resulting in crushing. For some minerals with hard texture or large volume that have not been fully crushed, they will be further compressed and sheared by the secondary crushing cavity formed by the crushing rods on the disc rollers, the rotor teeth, and the fixed teeth, ultimately ensuring that the three-dimensional dimensions of the discharged materials meet the production requirements.

Limestone Crusher Drive Device

Drive Device

Two independent drive units, each drive units includes: motor, high-speed end coupling, gear box, low-speed end coupling. The high-speed end coupling uses a hydraulic coupling to connect the motor to the gearbox. The gearbox adopts parallel shaft helical gear structure to meet the requirements of power transmission, speed ratio and torque under extreme load of the Limestone Crusher .

Toothed Roller

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.

Housing

Limestone Crusher housing is designed as a rigid host frame, and the housing is made of cast steel and connected by high strength bolts. Wear-resistant plates are installed around the inside of the housing, and comb shaped wear plates are installed on both sides of the housing to prevent excessive material from adhering to the crusher tooth rollers.

Side Plates

The side plates of the Limestone Crusher are integrally formed through high-quality casting technology, ensuring a stable and reliable structure. After precise processing by a high-precision CNC lathe, the side plates achieve strict mating accuracy during installation. This design not only extends the service life of key components but also ensures the smooth operation of the entire machine, providing continuous support for the equipment under high-intensity working conditions.

Lubrication Device

Limestone Crusher adopts centralized automatic lubrication system, it can be more oil filling times, oil filling time Settings, reliable to ensure the effective and reliable lubrication of each part. Automatic control of oil supply interval time, oil supply pressure is large, oil supply speed is fast, the bearing is fully lubricated effectively, so that the core part of the teeth roller bearing to achieve good lubrication, greatly extend the service life of the teeth roller.

Running Gear

The tramming device is installed at the bottom of the Limestone Crusher and driven by a motor to move along a track to the maintenance access, facilitating easy maintenance and avoiding disassembly. This design allows the equipment to move smoothly between the operating and maintenance areas, reducing manual labor and minimizing downtime during maintenance, thus improving operational efficiency.

The Feeding size of crusher 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.

Secondary Sizers Toothed Roller

01/

With The Low Crushing Rate, The Market Competitiveness Of The Finished Product Has Soared

At the Limestone Crushing Plant, the layering crushing method of traditional cone crushers often causes limestone to produce a large amount of needle-like and flake-like materials as well as internal cracks in the stones, resulting in a high proportion of powder and difficult to guarantee the quality of the finished product. Our Limestone Crusher crushes the materials into mainly cubic shapes, with high particle uniformity and extremely low over-crushing rate. It is an ideal choice for high-standard concrete aggregates.

02/

Not Afraid Of Wet And Sticky Materials, Continuous Operation Of The Production Line Is Guaranteed

If the moisture content of limestone is slightly higher, the cone crusher is prone to material blockage, resulting in production interruption and causing economic losses to the enterprise. Our Limestone Crusher, with its unique advantage of shear crushing, has extremely strong adaptability to wet and sticky limestone and can effectively solve the blocking problem, ensuring that the entire production line always maintains continuous and stable operation, reducing the losses caused by production interruptions.

03/

Outstanding High Output Capacity Helps Break Through Production Capacity Bottlenecks

For Limestone Crushing Plant production, production capacity is one of the key factors affecting efficiency. Our Limestone Crusher uses two toothed rollers to continuously bite and crush, with high processing efficiency. When processing limestone materials, its processing capacity is often superior to that of the same-level cone crushers. It can help you break through the production capacity bottleneck of the production line and achieve maximum production capacity.

04/

Low Initial Investment, Rapid Launch Of High-yield Projects

If your limestone crushing plant is planning a crushing project, choosing our Limestone Crusher can save you significant procurement costs compared to a cone crusher, given the same processing capacity requirements. The lower initial investment reduces the barrier to entry, allowing you to quickly set up and operate your production line.

05/

The Energy-saving Effect Is Remarkable, And The Long-term Operating Costs Are Significantly Reduced

Our Limestone Crusher is designed with an emphasis on energy-saving. It has a simple structure and efficient operation. Compared to cone crushers with the same processing capacity, it requires lower motor power and consumes less energy. Over the long term, it can significantly reduce the operating costs of your production line. Among them, the energy consumption cost can be reduced by more than 30%, saving a large amount of funds for the long-term development of the enterprise and improving the overall profit level.

06/

Maintenance Is Simple And Costs Low, Reducing Equipment Downtime Losses

The maintenance of cone crushers has always been complex and costly. When replacing wear-resistant parts, a large number of components need to be disassembled, consuming a lot of time. During the downtime, considerable production losses will occur. Our Limestone Crusher adopts a modular design for the tooth rollers. The maintenance operation is simple, the replacement of wear-resistant parts is convenient, and the maintenance cycle is long, which can minimize equipment downtime, reduce labor and component costs, and reduce production losses caused by downtime.

Submit your requirements and talk with one of our technical engineer about your project.

Contact Us For Best Price

A high quality mechanical products, must have excellent tooling equipment. In order to ensure its accuracy and meet the needs of large orders. Henan Excellent Machinery Co.,Ltd owns 140 sets of professional equipment, including Five-axis Gantry Machining-center, CNC Boring And Milling Machining Center, Vertical Machining Center, Vertical CNC Machining Center, Gantry Machining Center, Laser Cutting Machine, Laser Pipe Cutting Machine, Welding Robot Workstation, Lengthen Lathe, CNC Horizontal Machining Center, etc. Advanced processing and manufacturing equipment including Environmental Spraying Room and Heat Trea equipment and ultra large Surface Heat Treatment.

Left And Right Side Plate Blanking Process

Front And Rear End Cover processing

Left And Right Side Plate Machining Process

Left And Right Side Plate processing

Teeth Ring Internal Surface Machining Process

Teeth Ring Internal Surface processing

Teeth Base Processing

Teeth Roller Heat Treatment

At present, EXCT has fully passed ISO9001-2008 international quality system certification, complete quality system make sure that from the product development and design, production, procurement and supply to sales and service process has been effective quality controlled.

EXCT has a rigorous and skilled inspection team to ensure the success of product quality control. The quality inspection department has a strict testing process that runs through the stages of raw material procurement, production, and installation to ensure that every piece of equipment delivered to customers is qualified.

Current Detection

Voltage Detection

Shaft Temperature Detection

Vibration Detection

Noise Detection

Ultrasonic Flaw Detection

Hardness Detection

Coating Thickness Detection

Our Limestone Crusher covers more than 20 countries and regions all over the world. They are mainly used for crushing raw coal, coal gangue, lignite, coke, topsoil and other materials, and are used in coal-related industries such as thermal power plants, coal mining, coal washing plants and so on.

Submit your requirements and talk with one of our technical engineer about your project.

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Limestone Crusher are customized for each application material to provide the best configuration and meet all your requirements.engineers.

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

Note: Tooth configurations vary depending on the material type, infeed size and discharge size.

Configuration information is typical values for reference. Please contact our technical engineers for more assistance with equipment selection.

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.