stone crusher dry mud crusher roller type

Addressing Your Core Operational Challenges in Raw Material Processing

Are you facing these persistent issues in your primary crushing stage?

• Material Bridging and Hopper Hang-ups: Sticky, clay-bound or high-moisture aggregates cause frequent blockages, halting your entire feed system and requiring manual intervention. This can result in 30+ minutes of unscheduled downtime per occurrence, directly impacting your daily tonnage.
• Premature Wear on Crushing Elements: Abrasive silica content and compacted dry mud act as an aggressive grinding paste, rapidly deteriorating crusher liners and hammers. This leads to unpredictable maintenance cycles and a high cost-per-ton in replacement parts.
• Inconsistent Product Gradation: Fluctuating feed material density—from hard stone to clumps of dry mud—causes output product size to vary wildly, failing to meet specification and leading to downstream process inefficiencies or product rejection.
• High Operational Vibration and Stress: The shock load from processing heterogeneous materials transmits excessive stress to the crusher's foundation and structure, increasing the risk of unplanned mechanical failures and structural repairs.

What if your primary crusher could manage variable feed composition without faltering, maintain a consistent output, and reduce your cost of ownership? The solution lies in a machine engineered specifically for these conditions.

Product Overview: GD Series Roller Crusher for Stone and Dry Mud

The GD Series is a robust roller-type crusher designed for the primary reduction of mixed feeds containing hard stone, compacted dry mud, clay, and other cohesive materials. Its principle relies on compression and shear forces between two counter-rotating rollers.

Operational Workflow:

1. Feed Intake: Mixed material is fed into the hopper, which is designed with internal agitators to break up initial bridging.
2. Compaction & Crushing: Material is drawn into the gap between the two massive rollers. One roller is fixed while the other is hydraulically adjustable, allowing it to "give" when encountering uncrushable material.
3. Size Reduction: The rotating rollers apply high-pressure compression, fracturing stone chunks while simultaneously shearing and crumbling lumps of dry mud.
4. Controlled Discharge: Crushed product passes through the adjustable gap, ensuring a controlled top-size output directly onto the discharge conveyor.

Application Scope:
Ideal for quarry primary crushing, construction & demolition waste recycling, and mineral processing of clay-bound ores. This machine is particularly effective for materials with a moisture content up to 15% and a compressive strength under 250 MPa.

Limitations:
Not suitable for highly abrasive feeds without specific alloy options, or for processing pure metal ores. Maximum feed size is limited by roller diameter.

Core Features: Engineered for Performance and Reliability

• Hydraulic Gap Adjustment | Technical Basis: Computer-controlled hydraulic cylinders position the movable roller. | Operational Benefit: Your operators can fine-tune product size in seconds from a central control panel and the system automatically relieves pressure for tramp iron protection. | ROI Impact: Eliminates downtime from non-breakable objects and ensures consistent product quality without manual shim changes.

• Helical Roller Design | Technical Basis: Multi-tooth segments are arranged in a helical pattern across the roller face. | Operational Benefit: This design provides a pulling action that draws material inward, eliminating bridging and ensuring a steady feed rate for higher throughput. | ROI Impact: Increases average throughput by 15-20% compared to straight-tooth designs by mitigating feed stalls.

• Tungsten Carbide Overlay (TCO) Options | Technical Basis: Automated weld deposition of tungsten carbide on high-wear areas of the crusher teeth. | Operational Benefit: Extends service life in highly abrasive applications where silica content is a concern. | ROI Impact: Reduces liner replacement frequency by up to 60%, directly lowering your cost-per-ton for wear parts.

• Independent Drive Trains | Technical Basis: Two high-torque motors independently power each roller via fluid couplings or heavy-duty gearboxes. | Operational Benefit: Provides superior starting torque under load and allows one roller to be serviced while the other remains locked out. | ROI Impact: Enhances operational availability; maintenance tasks can be performed more safely and efficiently.

• Centralized Greasing System | Technical Basis: Automated lubrication pump delivers grease to all major bearing points on a timed cycle. | Operational Benefit: Ensures critical bearings are consistently lubricated even in high-dust environments, preventing premature failure. | ROI Impact: Prolongs bearing service life by an average of 35%, preventing costly unplanned outages.

Competitive Advantages

The following table quantifies the performance differential between standard impact hammer mills commonly used for similar applications and our GD Series roller-type crusher.

Performance Metric	Industry Standard (Hammer Mill)	GD Series Roller Crusher Solution	Advantage
Availability (%)	85-90% (due to wear part changes & blockages)	94-96% (protected hydraulics, no bridging)	+7% Uptime
Avg. Wear Part Cost/Ton ($)	$1.50 - $2.00	$0.80 - $1.20 (TCO dependent)	Up to 40% Reduction
Noise Level (dB at 1m)	105-110 dB (Requires hearing protection)	85-90 dB (Compression-based crushing) >60% Reduction in Noise Exposure
Fines Generation (-5mm %)	25-30% (High impact creates excess fines) <15% (Controlled compression minimizes fines)	<15% (Controlled compression minimizes fines) >50% Reduction in Waste Fines
Energy Consumption (kWh/Ton)	1.8 - 2.2 kWh/Ton <1 .5="" kwh="" ton="" td="">1>	<1 .5="" kwh="" ton="" td="">1>	Up to 30% Improvement

Technical Specifications

• Capacity Range: Model dependent; from 150 TPH (GD-1210) to 600 TPH (GD-1815).
• Power Requirements: Dual motor configuration from 2 x 75 kW to 2 x 250 kW.
• Material Specifications: Rollers fabricated from forged 42CrMo steel; standard teeth are AR400 steel with optional TCO or full manganese steel construction.
• Physical Dimensions (GD-1612 Model): ~7m (L) x 3.5m (W) x 3m (H).
• Feed Size: Maximum lump size of 800mm.
• Product Size Range: Adjustable from 50mm to 150mm.
• Environmental Operating Range: Ambient temperature from -20°C to +45°C; dust-protected bearings (IP65 standard).

Application Scenarios

Quarry Operation with High Clay Content

Challenge: A granite quarry faced constant feeder blockages due to surface clay layers after rain, causing daily downtime averaging two hours per shift during wet seasons.
Solution: Installation of one GD-1612 roller-type crusher as the primary unit ahead of the secondary cone crusher.
Results: Blockages were eliminated entirely at the primary stage; plant availability increased by over two hours per shift during wet periods; consistent feed size improved secondary cone crusher efficiency by an estimated eight percent.

Construction & Demolition Waste Recycling

Challenge: A C&D recycling plant struggled with its impact crusher's high wear costs from concrete with embedded rebar and its inability to process soil-laden demolition debris without clogging.
Solution: Implementation of a GD-1510 roller-type crusher equipped with tramp iron protection hydraulics.
Results: Wear part costs reduced by over half due to lower rotor speed; uncrushable metal contaminants pass through without causing damage; mixed loads containing soil blocks are effectively processed into usable aggregate base material.

Commercial Considerations

The capital investment for our stone crusher dry mud crusher roller type solutions varies based on capacity requirements:

• Standard Tier Models (<300 TPH): Positioned competitively against premium jaw crushers but offer operational savings that typically yield an ROI within eighteen months through reduced downtime alone.
• High-Capacity Tier Models (>300 TPH): Custom-engineered solutions often including integrated feeding systems; pricing reflects higher-grade materials like full TCO rollers.

Optional features include:

• Advanced automation packages with remote monitoring
• Dust suppression systems integrated into the housing
• Special alloy rollers for extreme abrasion resistance
• Walk-in service platforms for enhanced maintenance access

We offer comprehensive service packages ranging from annual inspections with wear part audits through full-service maintenance contracts that guarantee operational availability levels.

Financing options include equipment leasing through our partners or progress-based payment plans tailored for large capital projects managed by engineering contractors.

Frequently Asked Questions

Q1: Is this machine compatible with our existing primary screening setup?
Yes.The GD Series is designed as a direct replacement or supplement for jaw or impact primary crushers.Its discharge profile is compatible with standard vibrating grizzlies and feeder conveyors.We provide interface drawings during the quotation phase.

Q2:What is the typical installation time required?
For a prepared foundation,a standard unit can be mechanically installed within five working days.Electrical connection depends on site-specific conditions but typically adds another two days.A full project timeline will be provided upon order confirmation.

Q3:What does routine maintenance involve?
Daily visual inspections,a weekly check of hydraulic pressure levels,and monthly greasing system checks.The primary wear parts are tooth segments which can be replaced individually without removing entire rollers.Field data shows this reduces scheduled maintenance time by over forty percent compared to rotor replacement in impactors.

Q4:What are your commercial terms regarding delivery?
We operate on CIF Incoterms basis.Customers receive FOB pricing ex-works,freight insurance costs calculated separately.Delivery lead times range from twelve weeks depending on model specifications optional features selected current production schedule confirmed upon order placement firm commitment date provided within forty-eight hours order receipt deposit payment received accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process accordingly thereafter finalizing manufacturing scheduling process