On August 12, 2024, the "Limestone Crusher Equipment Procurement Project" publicly released by the client company on the National Public Resources Trading Platform completed the bid evaluation. Our company -EXCT won the bid and officially signed the contract as the technical supplier of the project. Three Limestone Crushers were delivered to the limestone mining and processing project for construction stone materials in Nanning, Guangxi. Among them, the processing capacity of two single units was not less than 2200 t/h, and that of one unit was not less than 1 200 t/h. This project mines 9.8 million tons of limestone annually, with a service life of approximately 17 years. The reliability of the equipment and its continuous production capacity directly determine the overall benefits of the mining area. The equipment has been delivered and is currently under installation.

Project background and pain points

The two hammer crushers originally owned by the customer clearly exposed significant defects such as large fluctuations in particle size and a relatively high return rate during the production process of limestone crushing. Especially when dealing with large-sized raw stone materials, hammer crushers often produce a large amount of fine powder, which triggers a series of chain problems:

Firstly, the return material volume on the return belt conveyor increases significantly, which means that secondary crushing treatment is needed to meet the strict particle size requirements of downstream processes;

Secondly, due to the frequent wear and tear of equipment and the continuous increase in energy consumption, the overall production efficiency has significantly declined.

Furthermore, the produced powder is difficult to be effectively recycled and reused, which not only causes a huge waste of resources but also poses a potential pollution threat to the on-site production environment.

Facing these urgent practical problems that need to be solved, the customer urgently needs to introduce a new type of crushing equipment, which must be capable of achieving precise particle size control, effectively reducing the return material rate, and adapting to the crushing requirements of materials with high humidity.

Core equipment parameters

Primary Limestone Crusher

It is suitable for crushing materials with a compressive strength of no more than 150Mpa

Feed particle size: 80mm≤D≤1200mm

Output particle size: 300mm

Crushing processing capacity: >2300/h

Secondary Limestone Crusher

It meets the crushing requirements for materials with a compressive strength of ≤150 mpa.

Feed particle size: D≤300mm;

Output particle size: 160mm;

Crushing processing capacity: >2300t/h;

Tertiary Limestone Crusher

It is suitable for crushing materials with a compressive strength of less than 150Mpa

Particle size :80mm≤D<200mm

Output particle size: ≤80mm

Crushing processing capacity: >1200t/h

Limestone Crusher performance

Motor: High-voltage motor (10Kv), power three to 400kw: Adopts ICE-34 standard, protection class IP55, frequency: 50HZ, insulation class F, stator winding uses high-quality copper core, large temperature rise margin, long service life, cooling method is IC411(air-cooled), motor is continuous duty SI. It can operate stably at full load for 16 consecutive hours every day and always maintain a normal working temperature.

Reducer: Model: No less than H3SH19/X3FS280 Specification: Equipped with a cooling system. Under no-load conditions, the temperature rise of the reducer oil pool should not exceed 40℃, and the maximum temperature should not exceed 70℃. Under normal working conditions, the temperature rise of the reducer oil pool should not exceed 60℃, and the maximum temperature should not exceed 80℃. Oil leakage is not allowed at all sealing points of the reducer.

Drum gear coupling: Equipped with safety pins for mechanical protection.

Bearings: The toothed roller bearings adopt double sealing, and the sealing parts are made of high-temperature and corrosion-resistant materials to ensure that dust and debris cannot enter. Lubrication is carried out through centralized lubrication.

Crushing roller teeth: Made of wear-resistant and impact-resistant alloy steel through integral casting and heat treatment, the service life is required to handle a processing capacity of ≥12 million tons.

Tooth roller shaft: The crushing tooth roller shaft is made of forged 40Cr, 42CMo or equivalent material specifications.

Automatic lubrication: The equipment is equipped with an explosion-proof automatic lubrication system. The intelligent lubrication device enables automatic oiling, adjustable oiling volume, automatic oil-free alarm, blockage alarm and other functions.

Customer feedback

The person in charge stated: "EXCT's Limestone Crusher has achieved precise control of particle size in actual production, with a significant reduction in backflow. The overall energy consumption is approximately 12% lower than that of the original hammer crusher." " Limestone Crusher performs exceptionally well when handling materials with high moisture content, effectively avoiding adhesion and clogging problems caused by high material moisture, and significantly enhancing the continuity and stability of the production line. In addition, the wear-resistant components of Limestone Crusher have a long service life, reducing the downtime and maintenance costs caused by frequent component replacement, providing a strong guarantee for the long-term efficient operation of the mining area. The customer expressed high satisfaction with the performance and service of the Limestone Crusher provided by EXCT, considering it a successful equipment upgrade and technological transformation.