Double-roll sand-making crusher
I. Overview: Why Choose a Double-Roll Sand-Making Crusher?
The double-roll sand-making crusher (dual-roll crushing technology) utilizes two counter-rotating rolls to apply compressive and shear forces to the material, crushing feed sizes of ≤60mm down to 2–12mm manufactured sand and stone powder in a single pass. Its core operational principle—"crushing via compression rather than impact"—distinguishes it from Vertical Shaft Impact (VSI) crushers. Key advantages include low over-crushing rates, minimal dust generation, and energy consumption per ton that is 30–50% lower than that of hammer crushers or VSI crushers. Consequently, it is the preferred choice for producing sand from medium-hard materials (such as river pebbles, limestone, and coal gangue) and for "crushing-instead-of-grinding" pre-grinding processes.
Bottom line: When the material's Mohs hardness is ≤7 and high stability in particle size distribution is required, this equipment generally outperforms hammer or impact crushing solutions of equivalent capacity in terms of unit production cost and ease of maintenance.
II. Typical Application Scenarios
1. River Pebble Sand Making
River pebbles have a high SiO₂ content. After primary crushing in a jaw crusher, they are fed into the double-roll sand-making crusher to consistently produce 0–5mm sand suitable for concrete. This setup is ideal for river remediation projects and sand-making plants, as a single unit can replace the traditional two-stage process of "hammer crushing + shaping."
2. Pre-grinding of Limestone, Gypsum, and Cement Clinker
Double-roll compression crushing is renowned for low dust and energy consumption. It is frequently paired in series with vertical mills or Raymond mills to implement a "crushing-instead-of-grinding" strategy, boosting the mill's hourly output by 15–25%.
3. Coal Gangue, Shale, and Construction Waste Recycling
When processing coal gangue, shale, or construction waste with a moisture content of ≤20%, the equipment avoids clogging or material buildup on the rolls. It transforms waste materials into manufactured sand and recycled aggregates, aligning with circular economy policies and green mining standards.
river pebble sand-making equipment
III. Key Equipment Advantages (Specifications → Benefits)
| Advantage | Technical Performance | Practical Value to the Customer |
|---|---|---|
| Adjustable output size | Hydraulic/shim-based roll gap adjustment; stepless adjustment of output size (2–12 mm) | One machine handles various gradation requirements; no secondary crushing needed |
| Low power consumption per ton | Compression crushing; 30–50% lower electricity consumption per ton compared to VSI crushers | Based on 50 t/h, saves approx. 80,000–150,000 RMB in annual electricity costs |
| Low over-crushing rate | Fines content (≤0.15 mm) controlled within 15% | Higher yield of finished product; significantly reduced costs for re-grinding tailings |
| Wear-resistant roll surface | High-chromium alloy roll surface; Rockwell hardness HRC55+ | Roll surface lifespan of 8,000–12,000 hours (limestone application); low annual maintenance costs |
| Strong adaptability to wet materials | Accepts feed moisture ≤20%; non-stick roll design | No production stoppage during rainy seasons; coal gangue/shale can be fed directly |
| Compact structure | Small footprint; mobile configuration available | Flexible production line layout; civil engineering costs reduced by over 20% |
IV. Key Specifications Table (2PG Series)
| Model | Roll Diameter × Width (mm) | Feed Size (mm) | Output Size (mm) | Processing Capacity (t/h) | Motor Power (kW) | Machine Weight (t) |
|---|---|---|---|---|---|---|
| 2PG400×250 | 400×250 | ≤25 | 2–8 | 5–10 | 5.5×2 | 1.3 |
| 2PG610×400 | 610×400 | ≤40 | 2–10 | 15–40 | 15×2 | 3.8 |
| 2PG750×500 | 750×500 | ≤45 | 2–12 | 25–60 | 22×2 | 6.5 |
| 2PG800×600 | 800×600 | ≤50 | 2–12 | 40–80 | 30×2 | 9.8 |
| 2PG1000×700 | 1000×700 | ≤60 | 3–15 | 60–120 | 45×2 | 15.5 |
Note: Processing capacity is rated based on limestone (bulk density: 1.6 t/m³); for hard materials such as river pebbles or andesite, apply a conversion factor of 0.7–0.85. Please provide material lithology and target gradation specifications for model selection.
V. Application Case: 50 t/h River Pebble Sand-Making Line in Vietnam
A client in Can Tho, Vietnam, utilized Mekong River pebbles as raw material to set up a production line featuring a PE500×750 jaw crusher, a 2PG800×600 double-roll crusher (sand maker), a YK1860 vibrating screen, and an XSD3016 wheel-bucket sand washer. Data from six months of operation shows: 0–5mm sand fraction accounts for 82%; fines content is 12%; the crushed sand's crushing value is 11% (meeting local standards for C30 concrete sand); and electricity consumption is 4.2 kWh per ton—a 38% reduction compared to the previous hammer crusher setup. The inspection cycle for the roll surface is 9 months, and hydraulic roll gap adjustment allows for product specification changes within 30 minutes; the client has subsequently ordered a second unit.
VI. Recommended Equipment
| Stage | Recommended Equipment | Function |
|---|---|---|
| Coarse Crushing | PE/PEX Jaw Crusher | Crushes raw ore to ≤60 mm; feeds the sand-making stage |
| Sand Making | 2PG Series Double-Roll Crusher | Primary sand-making unit; adjustable particle size (2–12 mm) |
| Screening | YK Circular Vibrating Screen | Grading and screening; separates qualified sand from oversize material |
| Sand Washing | XSD Wheel-Bucket or Spiral Sand Washer | Removes stone dust and clay; improves cleanliness (reduces clay content) |
| Fine Sand Recovery | Integrated Fine Sand Recovery Unit | Recovers lost fine sand; recovery rate >85% |
| Feeding & Conveying | ZSW Vibrating Feeder + Belt Conveyor | Ensures stable feeding and balanced production capacity |
VII. FAQ
1. How do I choose between this equipment and a VSI sand maker?
Choose the double-roll crushing solution if the material's Mohs hardness is ≤7, moisture content is high, or energy consumption is a concern (it offers 30–50% lower electricity consumption per ton and handles wet material). Choose a VSI crusher for high-hardness materials (like granite or basalt) requiring shaping or when extremely high standards for particle roundness are needed. The two can also be used in series: the roll crusher produces coarse sand, and the VSI shapes it, balancing cost-efficiency with particle quality.
2. Can it handle materials with high moisture content?
Yes. Roll-based compression crushing is insensitive to moisture; it accepts feed moisture up to 20% without sticking to the rolls or clogging the machine. This is a significant advantage over hammer crushers and VSI crushers, making it ideal for coal gangue, shale, and river pebbles mined outdoors during the rainy season.
3. How is the output particle size adjusted? How is roll wear handled?
The gap between the two rolls is adjusted via a hydraulic system or shims, allowing for stepless adjustment of the output particle size (2–12mm); changing the configuration usually takes less than 30 minutes. The roll surfaces feature high-chromium alloy or a hard-faced layer, offering a service life of approximately 8,000–12,000 hours in limestone applications; once wear limits are exceeded, they can be restored via hard-facing, and the roll bodies can be refurbished multiple times, thereby reducing the total cost of ownership.
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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