Vibrating Crusher - Efficient Stone Crushing Solutions
In traditional sand and gravel production lines, crushing and screening are usually two separate processes: materials first enter the crusher, and after discharge, are conveyed to a vibrating screen for grading. In closed-loop circulation, a return conveyor belt is also required. This process not only requires large equipment footprint and high energy consumption, but also suffers from severe over-crushing and high circulating load. The vibrating screen crusher (also known as a screen-crusher-integrated machine) deeply integrates the efficient grading capability of the vibrating screen with the particle shape optimization capability of the crusher, completing "crushing of oversize material + screening of undersize material" within the same machine body, pioneering a new path for intensive crushing.
I. What is a Vibrating Screen Crusher? — Equipment Definition and Core Concept
1. Integrated Screening and Crushing, a Structural Revolution
The vibrating screen crusher is not simply a vibrating screen mounted above the crusher; rather, it uses the vibrating screen body as the crushing carrier. The equipment mainly consists of a screen box, vibrator, crushing rollers (or hammers), and screen plate. After the material enters, materials smaller than the screen openings pass directly through the screen to become the finished product; materials larger than the screen openings are crushed by the crushing device during the vibrating conveyor process, and immediately pass through the screen after reaching the standard. This process completely eliminates the "return belt" and "circulating stockpile" of traditional processes.
2. Applicable Scenarios and Machine Types
• Double Roll Screening Crusher: Suitable for medium-hardness materials such as coal and limestone, with controllable finished product particle size and low pulverization rate.
• Vibrating Hammer Screening Crusher: Suitable for construction waste and coal gangue, with both crushing and impurity removal functions.
• Vibrating Jaw Screening Crusher: Suitable for pre-screening and pre-crushing of hard rocks such as granite and basalt.
II. Four Core Advantages of Vibrating Screening Crusher
Advantage 1: Shortened Process Flow, Reduced Investment in Belt Conveyors and Civil Engineering
The traditional "crushing-screening-return" three-piece set requires at least two belt conveyors and intermediate silos. The integrated screening and crushing machine directly achieves "one-time feeding, finished product output". Taking a 3 million-ton-per-year aggregate production line as an example, approximately 120 meters of belt conveyor can be reduced, saving over 500,000 yuan in investment.
Advantage Two: Significantly Reduced Over-crushing, Increased Finished Product Rate by 8%–15%
The vibrating screen crusher adopts a "crushing is screening, screening is separation" working logic. Once qualified particles are produced, they immediately leave the crushing zone, eliminating the over-crushing phenomenon in traditional crushers where "qualified materials continue to be crushed." For limestone sand production, the finished product rate can be increased from the conventional 65% to over 78%.
Advantage Three: Reduced Energy Consumption, Down by Approximately 20% in Electricity Consumption per Ton
Due to the elimination of ineffective crushing, and the lower energy consumption of vibrating conveyor compared to belt conveyor, the total installed power of the system is significantly reduced. In a cement limestone crushing plant in Shandong, the system was changed from "plate feeder + jaw crusher + impact crusher + vibrating screen" to a single "vibrating screen crusher," reducing the system's electricity consumption per ton from 1.8 kW·h to 1.35 kW·h.
Advantage 4: Enclosed Structure, Dust and Noise Reduction
The integrated screening and crushing machine adopts a fully enclosed box structure, with the vibration system and crushing system housed in a sealed chamber. Combined with a negative pressure dust removal interface, dust emissions at the operating point are reduced by more than 80%. Operating noise is 10-15 dB(A) lower than conventional production lines, meeting the requirements for green mine access.
III. Case Study: Integrated Screening and Crushing Machine Rewrites the Cost Account of "Hard Rock Processing"
Indonesian Andesite Sand and Gravel Production Base
Andesite Crushing
• Background: Andesite has high hardness and strong abrasiveness. The original process consisted of a jaw crusher + cone crusher + vertical shaft crusher + three vibrating screens, with a circulating load rate as high as 150%.
• Pain Points: Rapid wear of the return conveyor belt, high screen consumption, and excessive fine needle-like and flaky particles in the finished product.
• Technical Improvement Solution: Remove one cone crusher and one vibrating screen, and deploy two vibrating screen-type double-roll crushers in parallel as a medium and fine crushing unit.
• Results:
• Circulating load reduced to below 40%, main conveyor belt life doubled;
• Finished 0-5mm manufactured sand and gravel powder content controllably adjustable from 18% to 7%–12%;
• Overall production line energy consumption reduced by 22%, saving over 2.7 million yuan annually in electricity costs alone.
vibrating-&-crushing-plant
IV. Related Recommendations: How to Choose and Match?
Recommended Solution 1: High-Mud Content Ore Pretreatment
Vibrating Screen Crusher + Tension Screen
The vibrating screen crusher has strong anti-sticking and wet-wet capabilities. Combined with a tension screen at the front end, it further enhances fine-particle separation, effectively solving the problem of material blockage in high-mud content ore.
Recommended Solution 2: Mobile Construction Waste Processing Line
Tracked Mobile Screening and Crushing Station
Mounting the vibrating screen crusher onto a tracked chassis eliminates the need for fixed infrastructure, allowing for immediate production upon arrival. This is particularly suitable for resource recovery in urban demolition projects.
Recommended Solution 3: Underground Coal Mine Chamber Crushing
Ultra-Low-Height Vibrating Screen Double-Roll Crusher
The overall height can be controlled below 1.5 meters. It integrates screening and crushing, directly producing qualified-sized raw coal, significantly reducing dust during underground transportation.
V. Three Frequently Asked Questions (FAQs)
Q1: Is the screen plate prone to clogging? Can it handle wet, sticky materials?
A: The screen plate of the vibrating screen crusher is under continuous high-frequency vibration, possessing self-cleaning capabilities. For sticky materials with a moisture content of 8%–12%, flexible anti-clogging screens or elastic rod screen plates can be selected, reducing the clogging probability by more than 70% compared to traditional vibrating screens.
Q2: What is the maximum crushing ratio of the integrated screening and crushing machine?
A: A single-stage vibrating screen crusher can crush 500–700mm raw ore to below 50mm, achieving a crushing ratio of 10–15. For producing fine materials below 25mm, a vertical shaft impact crusher or sand making machine can be installed downstream.
Q3: What is the lifespan of the vibrator? Is daily maintenance complicated?
A: The vibrator bearings use oil-immersion lubrication and labyrinth seals, with a designed lifespan of no less than 25,000 hours. Daily maintenance only requires checking the wear of the rubber block coupling, the tension of the screen plate, and the lubricating oil level. A single person can complete a single inspection within 15 minutes.
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.
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