As a typical hard rock material, basalt has a Mohs hardness of 6-7, which poses a severe challenge to the equipment during the crushing process. Traditional crushing equipment generally faces problems such as low efficiency, severe wear and high maintenance costs when processing basalt. This article will deeply analyze the actual application case of CS160 cone crusher in a large basalt aggregate production line, revealing how it overcomes the problem of hard rock crushing through innovative design.
1. Project background:
The Mexican government project highway supporting aggregate project has an annual output of 2 million tons of high-quality basalt aggregates, requiring the finished product particle size to be 0-5mm, 5-10mm, and 10-20mm in three grades, and the needle-like content is less than 10%.
Analysis of technical difficulties
• Material property challenges: The high hardness of basalt causes the equipment wear rate to be 3-5 times that of ordinary limestone
• Capacity requirements: The hourly output needs to be stable at 180-200 tons
• Finished product quality: It must meet the strict standards of highway asphalt concrete aggregate
• Operating costs: The power consumption per ton of crushing is required to be ≤1.8kWh, and the life of wear-resistant parts is ≥800 hours
2. Technological breakthroughs of CS160 cone crusher
Core technology innovation
2.1 Optimization of laminated crushing principle:
• The crushing chamber design with dynamic adjustment is adopted to automatically match the optimal compression ratio according to the characteristics of basalt
• Measured data shows that the crushing efficiency is increased by 27% compared with traditional equipment
2.2 Wear-resistant system upgrade:
• The main shaft is forged with special alloy steel with a hardness of HRC58-62
• The liner uses a new composite material, and its life is extended by 40% compared with conventional manganese steel
2.3 Intelligent control system:
• Equipped with PLC automatic adjustment device, real-time monitoring of spindle position and power consumption
• Case shows that the response time for abnormal working condition identification is shortened to within 3 seconds
3. Actual operation data analysis | Performance parameter comparison table
| Indicators | Traditional equipment | CS160 | Improvement |
| Hourly output (t/h) | 150 | 195 | +30% |
| Electricity consumption per ton (kWh/t) | 2.3 | 1.65 | -28% |
| Lining plate life (h) | 500 | 850 | +70% |
| Needle-like content | 15% | 8% | -47% |
Economic benefit calculation
• Annual electricity cost saving: 2 million tons × (2.3-1.65) kWh/t × 0.8 yuan/kWh = 1.04 million yuan
• Reduce downtime loss: Reduce the number of wear parts replacement by 6 times per year, saving 8 hours each time × 195t/h × 60 yuan/t = 561,600 yuan
• Total annual benefit: more than 1.6 million yuan
4. Analysis of unique application value
4.1 Innovative solution for particle size control
Through the "pre-screening + closed-loop circulation" system design, CS160 has achieved:
The proportion of 5-10mm key particle size has increased from 35% to 48%
The over-particle control accuracy is ±2mm (the industry standard is ±5mm)
4.2 Changes in maintenance mode
Developed a "predictive maintenance system" that uses vibration sensors and lubricating oil analysis to warn of liner wear 120 hours in advance, reducing unplanned downtime to zero.
4.3 Breakthrough in environmental performance
The measured noise is controlled below 85dB (15 meters away from the equipment), and the dust emission concentration is 8mg/m³, which is 20% better than the national standard.
6. Customer testimony and industry impact
The project has become a provincial green mine demonstration project. After 14 months of continuous operation of the CS160 equipment:
• A total of 2.8 million tons of basalt have been crushed
• The comprehensive utilization rate of the equipment has reached 93.7%
• Obtained the "High-quality Aggregate Production Equipment" certification from the China Sand and Gravel Association
Conclusion: A new benchmark for hard rock crushing
The CS160 cone crusher has proved through this case that it not only solves the technical difficulties of basalt crushing, but also redefines the economic standards for hard rock processing. Its value is reflected in:
• The whole life cycle cost is reduced by 31%
• The aggregate quality reaches the standard of highway surface material
• The degree of intelligence leads the industry upgrade
Extended thinking: With the continuous improvement of the quality requirements of aggregates in the infrastructure industry, the selection of suitable crushing equipment has changed from a simple cost consideration to a strategic decision. The successful case of CS160 provides a replicable technical paradigm for basalt and other hard rock processing.
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