The traditional limestone crushing process usually combines jaw crushers with cone crushers, but in practical applications, there are many problems - including low crushing efficiency, high powder generation rate, high energy consumption, uneven product particle size, and high infrastructure and operation costs.
Our company's newly developed limestone crushing production line adopts a combination of primary sizer and secondary sizer, which can effectively replace the traditional crushing system. This solution has the advantages of higher crushing efficiency, more uniform particle size control, lower energy consumption, and significantly reduced equipment investment and maintenance costs, providing a more efficient, economical and environmentally friendly solution for modern limestone crushing operations.

The Limitations Of Traditional Crushers

High Energy Consumption And Operating Costs： The unit energy consumption of jaw crushers for crushing limestone ranges from 1.012 to 3.298 kJ/kg (approximately 0.28 - 0.89 kWh/t), and the energy consumption will increase significantly when processing water-saturated rocks. Although cone crushers have relatively high efficiency, their purchase cost and the cost of replacing wear parts are also considerable.

High Powder, Poor Particle Size And Block Formation Of The Material： Under high crushing ratios, jaw crushers and cone crushers are prone to over-crushing materials, generating a large amount of unnecessary fine powder, which reduces the yield of high-value aggregates and leads to resource waste. The products of jaw crushers usually have a relatively high content of needle and flake-shaped particles, which can affect the quality of the final concrete and asphalt mixtures.

Poor Adaptability To Materials Limestone mines are often accompanied by high-humidity and high-viscosity clay or shale. For such materials, traditional crushers are prone to blockage, causing production interruption and seriously affecting production efficiency. Cone crushers are particularly unsuitable for processing highly viscous materials with high moisture content.

The Environmental Performance Is Excellent. Traditional crushers generate significant noise and dust during operation. Data shows that the noise level of jaw crushers can reach 83-102 dB(A), and that of cone crushers is even higher, reaching 95-107 dB(A). In terms of dust emissions, jaw crushers typically have the highest emission levels among common crushing equipment.

The Technological Innovation And Core Advantages Of Mineral Sizer：

The Working Principle Of Innovation: The Mineral Sizer adopts a working principle of dual-toothed rollers rotating at low speed and high torque in opposite directions, breaking materials through the effects of shearing, stretching and splitting. This unique working method brings revolutionary advantages:

Lower energy consumption and operating costs: The energy is concentrated on crushing the materials rather than being wasted on the friction and vibration of the machine. The modular design of the wear parts (such as the toothed sleeve) makes replacement quick and easy, and they have a longer service life, significantly reducing maintenance costs and downtime.

Outstanding material handling capability It can easily handle various complex materials such as hard, soft, wet and sticky, and abrasive ones without clogging. For limestone raw materials containing a large amount of clay, the Sizer can effectively crush them and disperse the clay lumps.

Excellent particle size control Through the precise control of product size by tooth profile design and tooth roller gap, three-dimensional control crushing is achieved, resulting in uniform particle size of the output product and extremely low powder content. This not only increases the yield of high-value-added products but also makes the shape of the finished aggregate closer to a cube.