Shaping Crusher

7 month ago

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Henan Zhongyu Dingli Intelligent Equipment Co., Ltd.

7 month

Product details

DLPCZ Heavy-Duty Hammer Crusher — Advanced Hammer Crusher with Multi-Zone Shaping Technology

Hammer Crusher Equipment Overview

The DLPCZ Heavy-Duty Hammer Crusher is a new-generation crushing machine developed by Zhongyu Dingli in response to the common issues of material blockage and rapid hammer wear in traditional hammer crushers, based on over a decade of continuous optimization and extensive user feedback. Featuring a proprietary three-zone shaping system and an overhead through-type structure, this machine can independently handle the entire process of primary crushing, shaping, and sizing. With a maximum feed size of 1,200 mm and a maximum hourly output of 6,000 tons, its production capacity exceeds that of comparable products by 30%. It is suitable for medium-hard, brittle materials with a compressive strength of ≤120 MPa (such as limestone, dolomite, and bluestone), and performs exceptionally well under high-moisture conditions. It is widely used in the metallurgy, mining, building materials, and chemical industries.

Hammer Crusher Equipment Highlights

Extra-Large Feed Capacity and High Throughput: Maximum feed size of 1,200 mm, maximum hourly output of 6,000 tons, capable of processing wet materials, with a 30% increase in throughput compared to similar products

Three-Zone Shaping System: Crushing Zone (wavy impact plates for efficient primary crushing) → Shaping Zone (diamond-patterned impact plates for precise particle shaping) → Forming Zone (inverted triangle impact plates + adjustable clearance for final particle shaping); multi-zone collaboration ensures high-quality end products

Overhead Through-Feed Design: Top feed and bottom through-discharge prevent blockages and ensure safe discharge of large foreign objects

Adjustable Clearance Control: Adjustable clearance between hammers and movable impact plates allows precise control of output particle size and fines content, resulting in a reasonable particle size distribution

Wear-resistant hammer heads: Hinged connection and premium materials extend service life by 4–6 times

Patented rotor: 42CrMo main bearings, thermally bonded bimetallic hammer heads + wear-resistant sleeves, “one rotor, three lifespans,” significantly reducing maintenance costs

Robust and Durable: Dual-fixed design with internal positioning of the impact plates and external tensioning, volute-shaped housing, and stress-relieved through annealing

Easy Maintenance: Multiple access doors, hydraulic shaft puller, and quick-release design for wear parts

Hammer Crusher Applications

Suitable for crushing medium-hard, brittle materials with a compressive strength ≤120 MPa, including typical minerals such as limestone, dolomite, and bluestone. Widely used in the following fields:

Metallurgical Industry: Primary and secondary crushing of ore

Mining: Centralized crushing of medium-hard minerals such as limestone and marble

Building Materials Industry: Aggregate processing and stone shaping

Chemical Industry: Crushing and processing of chemical raw materials

Particularly suitable for materials with high moisture content; the over-top through-flow design effectively resolves the material blockage issues common in traditional hammer crushers.

Hammer Crusher Process Flow

A customized process designed for large-scale crushing of medium-hard, brittle materials:

Feeding Stage: Raw material (≤1200 mm) is uniformly fed into the crushing chamber via a feeder. Large pieces can be fed directly without pre-screening, reducing investment in upstream processes.

Primary Crushing Stage: A high-speed rotor drives the hammers to deliver high-speed impacts to the material. The material undergoes repeated collisions against the wave-shaped impact plates in the crushing zone, achieving efficient primary crushing.

Shaping Stage: The pre-crushed material enters the shaping zone, where diamond-patterned impact plates subject it to multi-angle rebound collisions, effectively rounding the edges and producing a near-cubic particle shape.

Final Shaping Stage: The material enters the final shaping zone, where inverted triangular impact plates, combined with adjustable clearances, perform the final shaping. Material that does not meet specifications is recirculated for further crushing, while qualified material is discharged through the gaps.

Discharge and Screening: The finished material is discharged through the bottom through-structure and can be connected to screening equipment for grading. Non-conforming material is returned for re-crushing, forming a closed-loop cycle that ensures a continuous and uniform particle size distribution of the final product.

The entire process line simplifies the traditional three-stage “primary crushing + secondary crushing + shaping” process into a single-unit operation, saving over 30% in equipment investment and floor space.

Services

Process Design: We provide customized crushing solutions based on the customer’s material characteristics, production capacity requirements, finished product specifications, and site conditions. This includes equipment selection, process flow design, plant layout planning, and return on investment analysis.

Equipment Manufacturing: Strictly adhering to the ISO quality management system, core components (rotors, hammers, and impact plates) are manufactured using high-quality alloy materials and advanced processes. The entire machine undergoes no-load test runs before shipment to ensure performance compliance.

Installation and Commissioning: A team of professional engineers travels to the site to supervise installation, complete equipment commissioning and trial runs with actual material, and provide systematic training for operators to ensure stable production.

Operation and Maintenance Management: We provide full-lifecycle operation and maintenance services, including regular inspections, guidance on the supply and replacement of wear parts, remote technical support, and equipment upgrade and retrofit solutions, thereby reducing the client’s operational and maintenance management burden.

Hammer Crusher Project Case Study

Johor, Malaysia Highway Aggregate Processing Project

Project Location: Johor, Malaysia

Equipment Configuration: DLPCZ-2018 Heavy-Duty Hammer Crusher × 1 unit

Processed Material: Limestone and bluestone mixture (compressive strength 78–105 MPa, moisture content up to 12% during the rainy season)

Design Capacity: 3,000 tons per hour

Project Background: The client supplies aggregates for a large-scale local highway construction project. Located in a tropical rainforest climate zone with a rainy season lasting up to five months, the material’s moisture content typically ranges between 8% and 12% year-round. The original traditional hammer crusher frequently experienced blockages and shutdowns, severely impacting delivery schedules.

Solution: A single DLPCZ-2018 heavy-duty hammer crusher was installed to replace the original three-stage process of “jaw crusher + cone crusher + shaping machine.” This single unit handles both primary crushing and shaping. Its top-through design effectively addresses high-moisture conditions, while adjustable clearance ensures precise control of the final product size.

Operational Results: Since commissioning, the unit has maintained stable output even under high-humidity conditions during the rainy season, completely eliminating material blockages and downtime. The finished product features a stable particle size distribution of 5–31.5 mm, meeting the strict specifications for highway surface course aggregates. Overall energy consumption has decreased by 22% compared to the original setup, and the equipment

Hammer Crusher Project Case Study

Road Aggregate Processing Project in Johor, Malaysia

Project Location: Johor, Malaysia Equipment Configuration: 1 DLPCZ-2018 Heavy-Duty Hammer Crusher Processed Material: Limestone and bluestone mixture (compressive strength 78–105 MPa, moisture content up to 12% during the rainy season) Design Capacity: 3,000 tons per hour

Operational Results: Since commissioning, the unit has maintained stable output even during the rainy season’s high-moisture conditions, completely eliminating blockages and downtime. The finished product size distribution is stable at 5–31.5 mm, meeting the strict specifications for highway surface course aggregates. Overall energy consumption has decreased by 22% compared to the original setup, and equipment investment costs were reduced by 35%. Eight months after commissioning, the customer purchased a second unit for Phase II expansion.

Technical parameters:

Model	Inlet size W×L ( mm )	Processing ( t/h )
DLPCZ1308	800 × 850	100～160
DLPCZ1512	1200 × 900	250～400
DLPCZ1815	1480 × 1200	400～900
DLPCZ1820	2000 × 1200	800～1500
DLPCZ2020	2010 × 1200	1200～1600

Hammer Crusher FAQ

Q: Does the DLPCZ Heavy-Duty Hammer Crusher experience material blockages when processing high-moisture feed? A: No. The equipment features an overhead through-flow design: material enters the crushing chamber from the top, and qualified particles are discharged through the bottom, while large foreign objects can also pass safely. This effectively resolves the material blockage issues common in traditional hammer crushers when processing high-moisture feed. Actual project feedback shows stable operation even under conditions with moisture content as high as 12%.

Q: How does the three-zone shaping system of the DLPCZ heavy-duty hammer crusher ensure the final product’s particle shape? A: The three-zone shaping system consists of the crushing zone, shaping zone, and forming zone, which work in sequence: the wavy impact plates in the crushing zone perform efficient primary crushing; the diamond-patterned impact plates in the shaping zone trim the edges of the material through multi-angle rebounding; and the inverted triangular impact plates in the forming zone, combined with adjustable clearances, perform the final shaping. This three-zone coordination produces a final product with a near-cubic shape, significantly reduces the fines content, and ensures a continuous and uniform particle size distribution.

Q: What is the service life of the hammers in the DLPCZ heavy-duty hammer crusher? What are the maintenance costs? A: The hammer heads of this equipment are made of thermally bonded bimetallic material and feature a hinged connection structure, extending their service life by 4 to 6 times compared to standard hammer heads. The patented rotor design achieves “three lifespans in one rotor,” allowing wear-resistant sleeves to be replaced individually without requiring a complete rotor replacement. Combined with a hydraulic shaft puller and multiple access doors, daily maintenance is convenient and efficient, significantly reducing overall maintenance costs.

Contact us today to receive a customized crushing solution and quote for the DLPCZ Heavy-Duty Hammer Crusher. With over a decade of industry expertise and a global presence serving more than 50 countries and regions, we ensure your crushing line operates more efficiently and with greater peace of mind.