The Crawler-mounted Integrated Impact Crushing and Screening Station represents the most common all-in-one solution. The main unit is a combined assembly that integrates a primary vibrating feeder, a heavy-duty vibrating screen, and an impact crusher. After the material undergoes pre-screening via the feeder, qualified fines are directly bypassed, while oversized lumps enter the impact crusher for reduction; the crushed material is then returned to—or fed into—the same screening unit for classification.
• Advantages: Compact structure; completes the entire crushing and screening process within a single machine; offers flexible site-to-site mobility; and is relatively cost-effective.
• Applicability: Suitable for scenarios where finished product specifications are not overly complex (e.g., primarily for the production of 0–31.5 mm mixed aggregates or backfill materials).
Special Considerations Regarding the Physical Properties of Coal Gangue
1. Wear Resistance:
• Impact Crusher Blow Bars/Impact Plates: Must be fabricated from ultra-high chromium alloy or composite ceramic materials to withstand highly abrasive components—such as quartz—present in coal gangue.
• Screen Media: The use of wear-resistant rubber or polyurethane screen media is recommended; these materials not only help reduce noise levels but also offer superior resistance to the abrasion caused by coal gangue compared to steel screens, while simultaneously minimizing screen blinding (clogging).
• Chutes and Liners: Critical wear zones must be fitted with wear-resistant liners or undergo wear-resistant hardfacing (weld overlay) treatment.
2. Anti-Clogging and Moisture Adaptability:
• Coal gangue may contain varying levels of moisture and clay/silt. The equipment must be designed with anti-clogging features in both the feeder and the screen box structure.
• While impact crushers possess a certain degree of adaptability to moist materials, if the clay content is excessively high, it may be necessary to incorporate a pre-treatment stage (e.g., a trommel screen or grizzly screen) prior to feeding the material into the crusher.
3. Iron Removal and Safety:
• It is strongly recommended to install a powerful, self-discharging magnetic separator (iron remover) on the feeder or the feed conveyor belt. This serves to remove potential contaminants—such as blasting caps, metal scraps, and iron objects—that may be mixed within the coal gangue, thereby protecting the downstream crusher; this constitutes a critical safety measure for production operations.
Frequently Asked Questions:
1: Can this equipment consistently achieve an output of 200 tons per hour? Will it experience rapid wear and tear when processing coal gangue?
Answer: Absolutely—it can consistently achieve that output. Our equipment is designed with a built-in capacity margin; while the rated capacity is 200 tons per hour, the actual design capability reaches 220–250 tons per hour. This ensures that your production requirements are met even when operating conditions fluctuate.
To address the highly abrasive nature of coal gangue, we have implemented specific reinforcement measures:
Core Wear Protection: The impact hammers (blow bars) and side liners of the impact crusher are cast from ultra-high chromium alloy (Cr26 grade or higher). This material offers wear resistance more than three times greater than that of standard high-manganese steel, making it specifically optimized for crushing materials such as coal gangue and construction waste.
Anti-Clogging Screening Design: The vibrating screen can be optionally fitted with wear-resistant rubber or polyurethane screen meshes. These materials not only resist abrasion but also effectively prevent wet, sticky materials from clogging the screen openings, thereby ensuring consistent and stable screening efficiency.
Comprehensive Wear Protection: Key material flow channels are fitted with replaceable wear-resistant liners. This significantly extends the equipment's service life under harsh operating conditions and effectively reduces your long-term operational and maintenance costs.
2: Can this mobile station complete both crushing and screening operations as a single standalone unit, or does it require a separate screening machine?
Answer: This depends on your specific requirements for the finished product. We offer two highly efficient configuration options:
Option A: Integrated Combined Station (Recommended for most scenarios)
This consists of a single crawler-mounted unit that integrates a heavy-duty feeder, an impact crusher, and a vibrating screen. It can independently execute the entire process—"feeding → pre-screening → crushing → screening → output"—to directly produce finished aggregates in various specifications (e.g., 0–31.5 mm). This option offers a more economical investment and maximum flexibility for site-to-site relocation, making it ideal for coal gangue utilization, backfilling applications, and the production of mixed aggregates.
Option B: Two-Unit Collaborative Station (For fine-grained classification)
This configuration consists of one crawler-mounted impact crushing station paired with one independent crawler-mounted mobile screening station. Following the crushing stage, the material is transported via conveyor belt to a screening station for fine classification, simultaneously yielding 3–4 different specifications of precisely graded aggregates (e.g., 0–5 mm, 5–10 mm, 10–20 mm, etc.). This solution delivers higher product quality and greater added value, though it entails a correspondingly higher investment.
Our technical consultants can recommend the most suitable solution for you, tailored to your specific product applications and budget.
