The combination of European-style jaw crushers and impact sand-making machines in a thousand-ton-class sand-making solution represents a major innovation in the field of sand and gravel processing. This solution has undergone comprehensive and in-depth optimization in terms of structural design and functional synergy, successfully achieving efficient collaborative operation between equipment, bringing revolutionary changes to the sand and gravel production industry. It not only significantly enhances the system's durability but also greatly boosts its production capacity, providing a solid foundation for the efficient and stable operation of large-scale sand and gravel production lines. The following are the specific design details of this solution:
1. Characteristics and adaptability of core equipment
European-style jaw crusher (primary crushing stage)
High-strength structural design: The European-style jaw crusher features a uniquely ingenious design, incorporating an integral cast steel bearing housing, forged eccentric shaft, and heavy-duty moving jaw assembly. These meticulously designed components enable it to withstand loads far exceeding those of conventional jaw crushers. In practical applications, it can efficiently and stably process various hard rocks with a maximum size of ≤1000mm, such as hard granite and basalt. In a large-scale sand and gravel plant, even when faced with extremely hard basalt, the European-style jaw crusher maintained high-efficiency and stable crushing operations, demonstrating outstanding crushing performance and laying a solid foundation for subsequent production processes.
Efficient crushing chamber design: Its unique symmetrical deep V-shaped chamber design not only cleverly increases the feed opening but also significantly optimizes the material flow path. The discharge opening size can be precisely adjusted via hydraulic wedges, with an adjustment range of 40–300 mm. This design ensures uniform particle size after coarse crushing, providing a good material foundation for subsequent fine crushing processes. At a well-known sand and gravel production company, the adoption of this efficiently designed European-style jaw crusher improved the uniformity of coarse-crushed material particle size by approximately 15%, significantly enhancing the processing efficiency and product quality of subsequent fine crushing equipment.
Thousand-ton production capacity performance: Taking the JC663 model as an example, this European-style jaw crusher achieves a maximum processing capacity of up to 1,250 tons per hour. This remarkable capacity fully meets the demands of large-scale sand and gravel production lines, providing strong support for efficient production. At a large-scale sand and gravel production base, after installing multiple JC663 models of European-style jaw crushers, the overall production capacity of the line was significantly enhanced, with daily output increasing substantially, bringing substantial economic benefits to the company.
Impact-type sand-making machine (fine crushing and shaping stage)
Wear-resistant and impact-resistant performance: The impact-type sand-making machine is equipped with high-quality alloy cutting heads and wear-resistant liners for the vortex chamber. These materials exhibit excellent wear resistance and impact resistance. Through the “stone-on-stone” working principle, they effectively reduce metal wear, thereby significantly extending the service life of the equipment and lowering maintenance costs. At a long-running sand and gravel plant, after adopting this impact-type sand-making machine, the wear rate of key components slowed significantly, maintenance intervals were extended, and maintenance costs decreased by approximately 20%.
Strong particle size controllability: Its closed-loop design allows the output particle size to be flexibly adjusted between 0 and 10 mm. This feature ensures that the produced finished sand has a rounded particle shape and excellent gradation, fully meeting the production requirements for high-standard sand and gravel. At a construction company with extremely stringent quality requirements for sand and gravel, the finished sand produced using this impact-type sand-making machine fully meets the concrete mix ratio requirements, thereby enhancing the quality and performance of the concrete.
II. Synergistic Effects of the Solution
Tightly Integrated Processes
After the European-style jaw crusher coarsely crushes the material to a semi-finished product of ≤200 mm, it is directly conveyed via a conveyor belt to the impact sand-making machine for fine crushing. This tightly integrated process avoids blockages in intermediate stages and significantly improves overall production efficiency. According to actual production data, the overall efficiency of the production line has increased by approximately 20% after adopting this synergistic solution. At a large sand and gravel plant, by optimizing process matching, the daily production capacity of the production line increased from 8,000 tons to 9,600 tons, with a significant improvement in production efficiency.
Significantly enhanced durability
The overload protection device of the jaw crusher's elbow plate combined with the hydraulic cover opening design of the impact-type sand-making machine effectively reduces damage to core components caused by abnormal operating conditions. Additionally, the centralized lubrication system of the European-style jaw crusher and the oil cooling technology of the impact-type sand-making machine significantly reduce maintenance requirements for the equipment. According to statistics, after adopting this solution, the equipment's failure rate decreased by approximately 30%, and maintenance costs also decreased by approximately 25%. At a sand and gravel plant that has been using this solution for an extended period, the average mean time between failures (MTBF) increased from 1,000 hours to 1,300 hours, and maintenance costs were significantly reduced, saving the company a substantial amount of operational costs.
Stable production capacity guarantee
The flywheel energy storage design of the jaw crusher balances power fluctuations, ensuring stable operation during the crushing process; while the high-speed rotor of the impact sand-making machine continuously performs shaping operations, ensuring the uniformity and consistency of the output particle size. The perfect combination of the two ensures a stable production capacity of over 1,000 tons per hour, providing a strong guarantee for production. In actual production, this solution has been successfully applied to multiple large-scale sand and gravel production lines, yielding significant economic and social benefits. At a certain large-scale sand and gravel production base, after adopting this solution, not only did production capacity stabilize and increase, but the quality of the produced sand and gravel also excelled, gaining widespread market recognition and bringing the company a good reputation and economic benefits.
