Double-Roll Sand-Making Machine
The double-roll sand-making machine (2PG series roll crusher) utilizes the principle of low-speed roll compression and crushing. When processing medium-hard materials such as limestone, river pebbles, andesite, and coal gangue, it stably produces graded sand (2–10mm). It consumes over 30% less electricity per ton compared to hammer or impact-type sand-making equipment and keeps the over-crushing rate below 15%. For enterprises involved in sand and aggregate production, construction waste recycling, and mineral processing that prioritize low operating costs and high sand yield, the double-roll sand-making machine offers a highly cost-effective solution.
I. Overview of the Double-Roll Sand-Making Machine: Working Principle and Equipment Structure
The double-roll sand-making machine is a type of roll crushing equipment featuring two crushing rolls that rotate towards each other. Material enters the gap between the rolls from the top inlet and is crushed through the combined effects of compression and shearing—occurring both between the roll surfaces and the material, and between the material particles themselves. The final particle size is precisely controlled by the gap between the rolls (the discharge opening); this is the fundamental characteristic distinguishing it from other sand-making equipment.
Its sand-making mechanism differs significantly from that of impact-type sand-making machines. Impact crushers rely on high-speed rotors to strike the material, resulting in high energy consumption, excessive dust, and significant over-crushing. In contrast, the double-roll sand-making machine employs low-pressure, slow-speed compression, resulting in a simple structure, minimal over-crushing, and uniform particle shape. The equipment comes standard with spring or hydraulic buffering devices; if uncrushable objects (such as metal debris) enter the machine, the rolls automatically retract to protect the unit from damage.
Key components: Crushing rolls, wear-resistant roll shells, frame, drive system, spring/hydraulic adjustment mechanism, and dust-proof sealing system.
2PG Roll Sand Maker
II. Typical Application Scenarios for Double-Roll Sand-Making Machines
Manufactured Sand for Aggregates: Production of manufactured sand from medium-hard materials such as limestone, dolomite, and river pebbles. The resulting 0–5mm sand can be used directly in concrete and mortar, serving as a substitute for natural river sand.
Construction Waste Recycling: Waste concrete and brick rubble are crushed into recycled sand aggregate using the double-roll sand-making machine, aligning with policies promoting the resource utilization of construction waste and the circular economy.
Mineral Processing Support (Secondary/Tertiary Crushing): Acts as secondary or tertiary crushing equipment to reduce ore to a finer feed size for the mill, thereby lowering energy consumption in downstream ball milling and increasing the processing plant's capacity.
Coal-based Material Processing: Fine crushing and granulation of brittle materials—such as coal gangue, coke, and raw coal—serving the building materials, chemical, and metallurgical industries.
Refractories and Chemical Raw Materials: Precision granulation of medium-hardness materials (e.g., corundum, silicon carbide, calcium carbide) to meet specific particle size requirements.
III. Core Advantages of the Double-Roll Sand-Making Machine
1. Low Electricity Consumption per Ton & Controllable Operating Costs: Low-speed compression crushing results in significantly lower electricity consumption per unit of output compared to impact or hammer crushers. For a 50 t/h production line, annual electricity savings can range from tens of thousands to hundreds of thousands of yuan, offering substantial long-term returns.
2. Low Over-crushing Rate & High Sand Yield: Precise adjustment of the discharge opening and a moderate crushing ratio prevent over-crushing. This ensures a high proportion of qualified sand particles, minimizes ineffective circulating loads in the screening circuit, and improves the overall sand yield.
3. Simple Structure & Low Maintenance Costs: With no hammerheads or high-speed rotors, daily maintenance focuses primarily on replacing worn roll shells. The split-design roll shells allow for partial replacement, reducing both the cost and labor hours compared to replacing a full set of hammerheads.
4. Strong Adaptability to Wet or Muddy Materials: Compression crushing eliminates high-speed material ejection channels, making the machine resistant to clogging when processing raw materials with 8%–10% moisture or clay content; it is well-suited for applications such as wet sand processing.
5. Environmentally Friendly: The machine operates in a fully enclosed manner; when paired with a bag-type dust collector, it achieves low-dust operation, meeting "green mine" standards and environmental impact assessment requirements.
IV. Technical Parameters (Typical Configuration for 2PG Series)
| Model | Roll Diameter × Width (mm) | Feed Size (mm) | Discharge Size (mm) | Capacity (t/h) | Motor Power (kW) |
|---|---|---|---|---|---|
| 2PG400×250 | 400×250 | ≤25 | 2–8 | 5–10 | 2×5.5 |
| 2PG610×400 | 610×400 | ≤40 | 2–10 | 13–35 | 2×15 |
| 2PG750×500 | 750×500 | ≤40 | 2–20 | 20–60 | 2×22 |
| 2PG1000×700 | 1000×700 | ≤50 | 3–30 | 30–90 | 2×37 |
Note: Capacity is calculated based on limestone (bulk density approx. 1.6 t/m³); actual capacity varies depending on material hardness, moisture content, and discharge opening settings. Please provide details regarding material lithology, feed size, and target product specifications; Baichen Heavy Industry offers one-on-one model selection and free test-run support.
V. Customer Case Studies
Case 1: Andesite Sand-Making Line in Indonesia.
A manufactured sand production line supporting a concrete mixing plant in Indonesia used andesite (Mohs hardness 6–7) as raw material. The plant originally utilized a hammer crusher, which required monthly hammer replacements and incurred high electricity costs. After switching to the 2PG750×500 double-roll sand maker, the fineness modulus of the finished sand stabilized between 2.6 and 3.0, electricity consumption per ton of sand dropped by approximately 35%, the service life of the roll shells extended to over six months, and the overall operating cost of the production line decreased significantly.
Case 2: Construction Waste Recycling Project in Mongolia.
A construction waste recycling project in Ulaanbaatar, Mongolia, processing approximately 300 tons of waste concrete and brick rubble per day. By utilizing a double-roll sand-making machine as the primary crushing unit for recycled sand, the output features low fines content and uniform particle shape. The recycled sand is used directly for road base layers and masonry mortar, achieving a closed-loop operation of "waste in, sand product out" and shortening the project payback period by approximately eight months.
Note: The above is a summary of typical operating scenarios; specific parameters vary by project. Detailed technical proposals tailored to specific rock types and production capacities are available upon request.
VI. Related Recommended Equipment
Beyond the sand-making machine itself, a complete manufactured sand production line typically requires the following equipment working in concert to form a "feeding–crushing–screening–washing" closed loop:
Vibrating Feeder (ZSW Series): Ensures uniform, continuous feeding to maintain stable, full-load operation of the sand-making machine.
Jaw Crusher (PE/PEX/C Series): Primary coarse crushing; reduces raw material size to meet the sand-making machine's feed requirements.
Impact Crusher/Cone Crusher (PF/CS Series): Secondary medium crushing and shaping; produces high-quality intermediate material from medium-hard feed.
Circular Vibrating Screen (YK Series): Product grading and closed-circuit screening; controls sand gradation.
Sand Washer (XSD Wheel-bucket/Spiral Type): Removes surface silt and fines; improves sand quality and market value.
Fine Sand Recovery Machine: Recovers fine sand lost during washing; increases overall sand yield and reduces waste.
VII. FAQ (Frequently Asked Questions)
Q1: How do I choose between a double-roll sand-making machine and an impact sand-making machine (VSI)?
A: The choice depends primarily on material hardness and operational cost priorities. Double-roll sand-making machines are suitable for medium-hard or softer materials (e.g., limestone, river pebbles, coal gangue), offering low-speed compression, low electricity consumption per ton, and simple maintenance. VSI sand-making machines are suitable for hard materials (e.g., granite, basalt) and applications requiring premium aggregates with superior particle shapes. If the raw material is highly abrasive hard rock, a VSI or a "cone crusher + shaping machine" combination is recommended.
Q2: Can the double-roll sand-making machine process wet materials? Will it clog?
A: Yes, it can. Double-roll sand-making machines utilize a crushing-by-compression mechanism without high-speed material ejection channels; consequently, they are significantly better suited for handling raw materials with 8%–10% moisture content or clay impurities compared to impact-type equipment. However, excessive moisture can reduce crushing efficiency and accelerate roller surface wear; it is recommended to keep the raw material moisture content below 10%. If moisture levels are high, a vibrating screen can be used for preliminary dewatering, or the roll gap can be appropriately widened.
Q3: What is the service life of the roller shells, and is the replacement cost high?
A: The service life depends on material abrasiveness, the roll gap setting, and the shell material (e.g., high-manganese steel, high-chromium alloy, or hard-faced composite). For limestone, the typical lifespan is 6–12 months, whereas for abrasive materials (such as andesite or river pebbles), it is approximately 3–6 months. The roller shells feature a segmented design allowing for partial replacement; both the replacement cost and downtime are lower than those associated with replacing a full set of hammers in a hammer-type sand maker, resulting in more controllable long-term maintenance expenses.
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.
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