In production processes, the stability and efficiency of the crushing system are critical to the overall operation of the production line. To address issues such as low output, severe hammer wear, uneven particle sizes, and frequent blockages in the double-rotor hammer crusher, a retrofit plan was implemented by adding a roller screening machine. This solution not only improves production efficiency but also significantly reduces energy consumption, making it an effective method for optimizing and upgrading the crushing system.
1. Issues with the Existing Crushing System
The current double-rotor hammer crusher system consists of a heavy-duty apron feeder and a double-rotor hammer crusher, with a processing capacity of approximately 1,250 tons per hour. Despite its strong crushing ability, the system faces the following challenges during operation:
- Over-crushing of Fine Materials: A large portion of the raw material consists of fine particles smaller than the desired final size. These fine materials continue to be processed in the crusher, causing unnecessary energy consumption and accelerated wear of the hammers and liners.
- Blockages Caused by Soil Content: The presence of soil in the raw materials often leads to blockages in the crusher, reducing efficiency and increasing maintenance costs.
- High Energy Consumption: As both large and fine materials are processed simultaneously, the energy consumption of the system increases, and the wear on the equipment accelerates, raising overall operating costs.
2. The Retrofit Plan with Roller Screening Technology
To enhance the performance of the crushing system, a roller screening machine was installed. This machine performs both feeding and screening functions, allowing fine materials to be separated before entering the crusher, ensuring that only large materials are crushed. The key steps in the retrofit process included:
- Removal of Old Components: Parts such as the upper housing, side housing, and rear door of the crusher were either removed or replaced, and the apron feeder supports were realigned.
- Installation of the Roller Screening Machine: A roller screening machine was installed between the crusher and the apron feeder, allowing the screening function to separate fine materials prior to crushing.
- System Connection Optimization: Custom-made transition housings and upper covers were added to ensure proper sealing and stability between the new equipment and the existing system.
3. Results of the Retrofit
Following the retrofit, the double-rotor hammer crusher system achieved significant improvements in both production and energy efficiency:
- Increased Production: The screening machine separates fine materials before they enter the crusher, preventing over-crushing. This allows the crusher to focus on processing larger materials, resulting in a noticeable increase in overall production.
- Energy Savings: The system’s energy consumption was significantly reduced, and wear on the hammers and liners was minimized. This has extended the maintenance cycle of the equipment and lowered operating costs.
- Reduced Blockages: The roller screening machine efficiently separates sticky and wet materials, reducing the frequency of blockages in the crusher and improving the system’s operational stability, especially in wet conditions or when raw materials contain high soil content.
4. Conclusion
The retrofit of the double-rotor hammer crusher system, by adding a roller screening machine, has successfully addressed the challenges of low output, excessive wear, and frequent blockages. By focusing on crushing larger materials and pre-screening out fine and sticky particles, the system has improved production efficiency, reduced energy consumption, and enhanced operational stability. This energy-saving retrofit offers valuable insights for future upgrades in the industry’s crushing systems.
This upgrade demonstrates how technological improvements in crushing systems can increase production efficiency and save energy. The application of the roller screening machine provides an innovative solution to bottlenecks in system operations, particularly when dealing with complex raw materials. by chenjun jin
