20 mm crushed sandstone

1. PAIN-POINT DRIVEN OPENING

Are inconsistent feed gradations and abrasive fines crippling your aggregate production efficiency? When processing 20 mm crushed sandstone, operational bottlenecks directly impact your bottom line. Common challenges include:

• Premature Wear Costs: The high silica content in sandstone accelerates wear on crusher liners, screens, and conveyors, leading to unplanned downtime and replacement part costs exceeding $50,000 annually for mid-sized operations.
• Inconsistent Product Yield: Maintaining a precise 20 mm top size and desired cubical shape is difficult with improper crushing stages, resulting in off-spec material that is either rejected or sold at a significant discount.
• High Fines Generation: Excessive fines production during crushing not only represents lost revenue from the primary product but also creates dust control issues and additional handling costs.
• Throughput Inefficiency: Inadequate equipment selection for the material's abrasiveness leads to frequent clogging, reduced capacity, and failure to meet daily tonnage targets.

Is your current setup equipped to handle the specific demands of 20 mm crushed sandstone while maximizing yield and controlling operational expenditure?

2. PRODUCT OVERVIEW: Tertiary/Horizontal Shaft Impact (HSI) Crusher Plant for Precision Aggregates

This engineered crushing circuit is designed for the efficient reduction of sandstone feedstock into high-value, specification 20 mm crushed sandstone aggregate. The system prioritizes product shape control and minimizes wasteful fines generation.

Operational Workflow:

1. Pre-Screened Feed: Primary crushed sandstone (<100 mm) is pre-screened to bypass material already at 20 mm or smaller, increasing circuit efficiency.
2. Precision Reduction: Oversize material is fed into a horizontal shaft impact (HSI) crusher configured for tertiary crushing, utilizing a rock-on-rock or rock-on-anvil principle for optimal inter-particle breakage.
3. Closed-Circuit Sizing: Crushed material returns to a sizing screen. On-spec 20 mm crushed sandstone is diverted to product stockpiles.
4. Recirculation: Oversize material is recirculated back to the HSI crusher input, ensuring complete processing.

Application Scope & Limitations:

• Ideal For: Producing premium, cubical aggregates for concrete asphalt, drainage layers, and construction sub-base from medium-abrasive sedimentary rock like sandstone.
• Limitations: Not suitable for highly abrasive feeds (e.g., some quartzites) without specific liner configurations. Maximum feed size is dependent on primary crushing output; typically requires input below 100-150 mm.

3. CORE FEATURES

• Hydraulic Adjustable Curtains | Technical Basis: Dynamic gap setting control via hydraulic cylinders | Operational Benefit: Allows operators to fine-tune the distance between aprons/liners and the rotor in real-time to maintain target product size (20 mm) as wear occurs | ROI Impact: Reduces product variation by up to 40%, ensuring consistent specification compliance and premium pricing

• Multi-Port Rotor & Hybrid Liners | Technical Basis: High-chrome white iron castings combined with martensitic steel wear parts | Operational Benefit: Optimized rotor geometry manages feed velocity while hybrid liners provide superior resistance to sandstone's abrasive silica content | ROI Impact: Extends wear life by an average of 30%, decreasing cost-per-ton for wear parts and related maintenance downtime

• Patented Cascade Flow System | Technical Basis: Controlled internal material trajectory within the crushing chamber | Operational Benefit: Increases rock-on-rock breakage ratio over rock-on-metal contact for producing more cubical particles in the target 20 mm range while reducing fines generation | ROI Impact: Improves yield of in-spec product by up to 15%, directly increasing salable tonnage

• PLC-Automated Process Control | Technical Basis: Integration of crusher motor amps, feed rate sensors, and vibration monitors into a central programmable logic controller (PLC) | Operational Benefit: Automatically regulates feeder speed to maintain optimal chamber loading, preventing choke or stall conditions | ROI Impact: Protects drive components and sustains peak throughput efficiency, contributing to a projected 8-12% increase in average daily tonnage

• Modular Access & Service Design | Technical Basis: Hydraulically opening crusher housing and externally accessible wear part brackets | Operational Benefit: Enables safe liner inspection and replacement in hours versus days; major components can be serviced without dismantling adjacent structures | ROI Impact: Cuts planned maintenance downtime by over 50%, significantly improving annual equipment availability

4. COMPETITIVE ADVANTAGES

Performance Metric	Industry Standard for Sandstone Crushing	This HSI Circuit Solution for 20 mm Crushed Sandstone	Advantage (% Improvement)
Wear Part Cost per Tonne	$0.85 - $1.10 / tonne	$0.60 - $0.75 / tonne	~25% Reduction
Product Shape (Cubicity Index)	Avg. Ratio of 0.7 - 0.75 (Flaky)	Avg. Ratio of >0.8 (Cubical)	>10% Improvement
Yield of On-Spec (+/-2mm) Product	~75-80% of throughput	~85-90% of throughput	~12% Increase
Electrical Power Consumption	Fixed speed drive systems	Load-responsive VFD drives on conveyors & feeders	Up to 15% Reduction

5. TECHNICAL SPECIFICATIONS

• Capacity Rating: Model-dependent; standard configurations from 150 - 450 tonnes per hour of finished 20 mm crushed sandstone.
• Power Requirements: Primary HSI crusher drive ranges from 300 kW to 600 kW. Total plant connected load includes screens and conveyors.
• Material Specifications: Engineered for sedimentary rock with Abrasion Index (AI) <0.5 and Compressive Strength <150 MPa. Optimal moisture content <5%.
• Physical Dimensions (Typical Skid-Mounted Module): Length: ~18m; Width: ~4m; Height: ~5m.
• Environmental Operating Range: Full operation from -20°C to +45°C ambient temperature with appropriate hydraulic oil specifications.

6. APPLICATION SCENARIOS

#### Quarry Operation Producing Concrete Aggregate | Challenge: A quarry's existing cone crusher produced excessive flaky particles (>25% elongation index) when making 20 mm crushed sandstone, leading to concrete workability issues and customer complaints.| Solution: Replacement with a configured HSI tertiary crushing circuit focused on high cubicity output.| Results: Particle shape met BS EN standard for coarse aggregate (<15% elongation index). This allowed entry into a premium concrete supply contract, increasing margin by $3/tonne on average monthly production of 25k tonnes.

#### Construction Materials Plant Expanding Product Line| Challenge:The plant needed to add a specification drainage aggregate (20mm single size) but their secondary jaw crusher could not efficiently produce the required narrow grading band.| Solution:A compact tertiary HSI plant was installed downstream of their secondary circuit specifically dedicatedto producing clean,single-size 20mmcrushedsandstone.| Results:Achieved consistent grading with less than5% oversizeand8%fines.Plantaddedanewhigh-marginproductlineusingexistingfeedstockwithminimalreconfiguration,increasingoverallsiteutilization.

7.COMMERCIAL CONSIDERATIONS

Equipmentisavailableinthreetiersbasedoncapacityandautomationlevel:
• Base Tier(150-250TPH):IncludescoreHSIcrusher,basicscreen,andPLCstart-up.Focusedonreliabilityandcapabilityfor 20mmcrushedsandstoneproduction.
• PerformanceTier(250-400TPH):Addsautomatedfeedcontrol,VFDsontopconveyors,dustsuppressionsystem,andadvancedwearmonitoring.
• PremiumTier(400+TPH):Fullplantoptimizationsuitewithpredictivemaintenanceanalytics,mobileremoteaccess,andextendedwarrantycoverage.

Optionalfeaturesincludewearpartkits,dustenclosuresforstringentcompliance,andcustomizeddischargeconveyorconfigurations.Servicepackagesrangefromannualinspectionplanstofull-siteoperationalsupportwithguaranteedavailability.Financingoptionsincludeoperationalleaseagreements,tailoredto matchproductionseasonalityandcashflowrequirements.

8.FAQ

Q:Whatprimarycrushersetupiscompatiblewiththissystemfor 20mmcrushedsandstoneproduction?
A:Thecircuitisdesignedtoreceiveprimarycrushedmaterialtypicallyunder100-150mm.Itworksoptimallydownstreamofajaworprimarygyratorycrusherthatprovidesaconsistentfeedgradation.

Q:Whatistheexpectedimpactonfinesgeneration(-4mmmaterial)?
A.Fielddatashowsareductioninexcessivefinesgenerationbyapproximately18-25%comparedtoconventionalcompressioncrushers,whentargeting 20mmtopsize,dueenhancedrock-on-rockbreakage.

Q:CanyouquantifytheROItimelineforthisinvestment?
A.Basedonhistoricaloperationsproducing 200ktonnesannuallyof 20mmcrushedsandstone,thecombinedsavingsfromwearparts,increasedyield,andhigherthroughputtypicallydeliverapaybackperiodof18-30months.Detailedproformamodelsareprovidedduringtheapplicationreview.

Q:Arewearpartsproprietaryoravailablefromthird-partysuppliers?
A.CriticalrotorassembliesandhybridlinersareengineeredasOEMpartsforperformanceguarantee.Non-criticalwearplatesandstandardhardwarecanbesourcedfromqualifiedthird-partysuppliersifdesired.

Q:Whattrainingisprovidedforouroperatorsandmaintenancestaff?
A.Commissioningincludesacomprehensiveonsiteoperatorcertificationprogramfocusingonsizedadjustment,routinechecks,andbasicdiagnostics.Maintenancetechniciantrainingisalsoavailablecoveringlinerchangeproceduresandsystemdiagnostics