We recently received a typical customer inquiry: "We need a jaw crusher with a capacity of 20 tons/hour to crush concrete bricks, slag, and waste formwork (feed size 0-100 mm) to 0-7 mm."
This raises a core question: Can a traditional jaw crusher achieve ultrafine output of 0-7 mm? The answer is: very difficult and uneconomical. The core advantage of a jaw crusher lies in primary crushing (coarse crushing). Its working principle is to crush materials through the periodic compression of the moving jaw. The output particle size is usually greater than 20 mm, and the product has a high proportion of needle-like and flaky particles. Using it for fine crushing operations requiring 0-7 mm is like carving ivory with an axe—inefficient and with a low yield.
Solution: Multi-stage Crushing and Core Equipment Recommendation
For the recycling needs of construction waste such as concrete bricks, slag, and waste formwork with a feed size of 0-100 mm and an output size of 0-7 mm, we recommend a classic two-stage crushing, screening, and closed-loop circulation process. This solution can achieve your goals efficiently and economically.
PE Jaw Crusher for sale
First Stage: Coarse Crushing - Jaw Crusher
• Function: Performs preliminary crushing of mixed materials ranging from 0-100 mm, providing a uniform and stable feed for the second stage of fine crushing (typically crushing to 0-30/40 mm).
• Recommended Model: PE series deep-cavity jaw crusher. Its robust structure makes it particularly suitable for crushing materials with high compressive strength, such as concrete bricks. It is less prone to jamming by metal impurities in slag, operates stably, and is an ideal choice for coarse crushing.
Sand Making Machine
Second Stage: Fine Crushing and Sand Making - Vertical Shaft Impact Crusher (Sand Making Machine)
• Function: This is the key equipment for producing 0-7 mm finished products. It uses the "stone-on-stone" or "stone-on-iron" principle to subject the coarsely crushed material to high-speed impact and grinding, perfectly producing high-quality recycled aggregate with a particle size between 0-7 mm.
• Core Advantages:
◦ Adjustable discharge particle size: By adjusting the rotation speed, feed rate, and flow pattern, the distribution of the finished product within the 0-7 mm range can be precisely controlled.
◦ Excellent Particle Shape: The produced particles are cubic with a reasonable gradation, far exceeding the needle-like and flaky products of jaw crushers, making it a high-quality alternative to natural sand.
◦ High Efficiency and Energy Saving: For concrete recycled materials and slag with medium to low hardness, its crushing efficiency is far higher than that of fine crushing using a jaw crusher.
Supporting Equipment: Vibrating screen and conveying system
• A multi-layer vibrating screen is required in the closed loop to return materials larger than 7 mm to the sand making machine for further crushing, ensuring that all final products meet the required standards.
Advantages and Value of the Solution
1. High Product Yield: Specialized two-stage crushing ensures maximum output of the 0-7 mm target particle size, far exceeding the operation of a single jaw crusher.
2. High Added Value of Products: The produced 0-7 mm recycled fine aggregate has good particle shape and excellent gradation, suitable for producing blocks, paving bricks, or as roadbed subbase, with high market value.
3. Low Operating Costs: Each piece of equipment performs its specific function, resulting in low wear, low energy consumption, strong system stability, and significant overall benefits.
4. High Adaptability: Easily handles mixtures of crushed concrete bricks, slag, and waste formwork, with strong resistance to fluctuations.
Success Story Sharing
A construction waste recycling project in East China faced the exact same needs as yours. Initially, they tried repeatedly adjusting a large jaw crusher to obtain fine aggregate, but the capacity was less than 5 tons/hour, and the product had too many needle-like and flaky particles, making it unsellable.
After adopting our recommended "jaw crusher + vertical shaft impact crusher" solution:
• Final Capacity: Stable at 22-25 tons/hour.
• Finished Product Particle Size: 0-5mm accounted for over 45%, and the overall pass rate for 0-7mm was 100%.
• Product Application: The produced recycled fine aggregate was entirely purchased by a local environmentally friendly brick factory, achieving considerable economic benefits.
Related Equipment Recommendations
• PE400×600 Jaw Crusher: Suitable for coarse crushing operations with a capacity of 20-30 tons/hour; the feed opening size is sufficient to accommodate 100mm concrete blocks.
• VSI-7611 Vertical Shaft Impact Crusher: A medium-sized sand making machine, ideal for fine crushing and sand making needs of 20-30 tons/hour, and the "heart" of the machine for achieving the 0-7 mm output target.
• 2YK1860 Vibrating Screen: A double-layer screen that efficiently separates 0-7 mm finished products and returns larger materials to the crusher.
Frequently Asked Questions (FAQ)
Q1: Can I achieve 0-7 mm output with just one jaw crusher?
A1: Technically, it can be partially achieved by drastically reducing the outlet size, but this will lead to a sharp drop in capacity (possibly below 5 tons/hour), abnormally accelerated equipment wear, extremely poor product particle shape, and extremely uneconomical operation. We strongly discourage its use.
Q2: Is the equipment prone to damage when processing slag and waste mold shells?
A2: Slag may contain metals, and waste mold shells (usually resin sand) have low hardness but may be tough. The jaw crushers and vertical shaft impact crushers we recommend are designed with resistance to excessive iron and adaptability to perse materials in mind. Key components use wear-resistant materials, and wear can be reduced by adjusting the process.
Q3: What is the investment and payback period for this two-stage crushing solution?
A3: Although the initial investment is higher than that of a single unit, due to the high value of the finished product, the achievement of production capacity targets, and stable operation, the investment can usually be recovered within 1-2 years through the sale of high-quality recycled aggregates. In the long run, its economic benefits far exceed those of an unreasonable single-unit solution.
About of Baichy Heavy Industry
Baichy Heavy Industry is a high-tech mining equipment company integrating R&D, manufacturing, sales, and after-sales service. Focusing on crushing, grinding, and mineral processing equipment, we provide professional solutions to our customers. We are ISO9001:2015 、certified, and our products include mobile crushing palnts, crawler crushing plant, construction waste crushing plants, jaw crushers, sand making machines, cone crushers, fine crushers, grinding mills, ball mills, etc., all with reliable performance to meet diverse project needs.
Our advantages:
• Professional pre-sales support: Free project design and comprehensive solutions to help you accurately select the right equipment;
• Comprehensive on-site service: Providing installation guidance and worker training to ensure smooth equipment commissioning;
• Reliable after-sales guarantee: A complete after-sales system, timely response to technical inquiries and equipment maintenance, ensuring long-term stable operation.
To protect your rights, please contact us through the following official channels for professional service:
Official Website Customer Service
WhatsApp: 0086-15093222637
Email: [email protected]
We are committed to providing high-quality equipment and full-cycle services to deliver comprehensive intelligent solutions for the global mining industry!
