High Efficiency Rock Shaper for Manufactured Sand Making

5 month ago

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Henan Zhongyu Dingli Intelligent Equipment Co., Ltd.

9 month

Product details

Hammer crushers are specifically designed for mining and quarrying applications

Hammer Crusher Equipment Highlights

The preferred solution for efficient primary and secondary crushing in mining and quarrying operations: a single machine handles both coarse and fine crushing, eliminating the need for two separate main units (jaw crusher and impact crusher), thereby reducing equipment investment, shortening the process line, and minimizing the required construction footprint.

Three-chamber grinding: Three impact zones sequentially perform coarse crushing → medium and fine crushing → grinding and shaping, resulting in aggregates with low flakiness and low elongation, a smooth gradation, and the ability to screen directly for finished products.

Compact and easy to maintain: The three-chamber design does not increase the overall machine size, and lubrication points are concentrated at ground level or on the side of the platform, eliminating the need for entry into the machine during routine maintenance.

Automatic Lubrication (Optional): Timed, metered oil injection into each bearing prevents bearing seizure caused by manual lubrication errors, making it ideal for large-scale production lines or remote mines.

Low Dust and Low Noise: Compared to a two-stage process, this design eliminates one transfer step, reducing dust generation points and easing environmental compliance pressures.

Comprehensive Product Range: Multiple models ranging from tens to hundreds of tons per hour, suitable for various applications including building materials aggregates, cement raw materials, and concrete aggregates, with support for turnkey line configurations.

Hammer Crusher Application Scenarios

Building Material Aggregate Production Lines:Replaces the two machine combination of jaw crusher and impact crusher, with a single unit handling everything from primary crushing of raw rock to aggregate shaping, proceeding directly to vibrating screen classification.

Limestone Preparation for Cement Plants: Crushes large limestone blocks from quarries to the feed size required for cement production, ensuring stable and continuous feeding to the clinker production line.

Small and Medium Sized Mining Crushing Stations: For small and medium sized mines with limited space and a production capacity of 200–300 t/h, the single unit solution significantly reduces the required civil engineering area and the number of equipment units.

Aggregates for Concrete Batching Plants: The aggregates feature a rounded shape and continuous gradation, resulting in superior concrete workability, reduced admixture usage, and lower mix design costs.

Hammer Crusher Customized Process Flow

Complete Single-Stage Limestone Hammer Crushing Process From Raw Stone to Finished Product in a Single Step:

① Feeding: A vibrating feeder uniformly feeds raw stone ≤700mm

② Primary Crushing: High-speed hammers deliver an initial powerful impact, reducing large chunks to medium-sized particles

③ Secondary Crushing and Shaping: Three-chamber impact: The second chamber performs medium-to-fine crushing to reduce particle size, while the third chamber grinds and rounds off sharp edges

④ Screening: Vibrating screens classify the material; finished product is sent directly to storage

⑤ Dust Collection: Baghouse dust collection ensures emissions meet standards

Key Features of the Three Chamber Design: The first chamber performs coarse crushing, reducing large chunks of 600–700mm to medium particle size; the second chamber performs medium-fine crushing, where material rebounds off the liner plates for further reduction; the third chamber grinds and shapes the material, smoothing edges to produce rounded particles with a smooth gradation.

Solution Comparison: The traditional two-machine setup requires two main units (a jaw crusher and an impact crusher) plus an intermediate conveyor belt, resulting in a large civil engineering footprint, numerous maintenance points, and increased dust and noise from two material transfers. This single-stage hammer crusher solution integrates coarse and fine crushing into a single unit, eliminating the intermediate conveyor belt and the cost of one main unit. It features a smaller civil engineering footprint, fewer potential failure points, and one fewer material transfer, making it easier to comply with regulations due to lower dust and noise levels.

Services

01 Solution Design

Based on feed size, target output, and finished product specifications, we provide crusher model selection, motor power calculations, and foundation drawings. We also offer complete production line packages (feeder, hammer crusher, vibrating screen, conveyor).

02 Equipment Manufacturing

In house R&D and manufacturing with full process quality control. Key components (hammer heads, liners, bearing housings) are made of high wear resistant materials. Strict whole machine commissioning and testing are conducted before shipment to ensure quality.

03 Installation and Commissioning

We dispatch professional engineers to the site to guide installation and commissioning, and train operators in key procedures such as hammer wear inspection, impact liner replacement, and discharge gap adjustment.

04 Operation and Maintenance Management

We provide a one year warranty on the whole machine and lifetime technical support.

Hammer Crusher Overseas Project Case Studies

Cambodia Phnom Penh Building Materials Aggregate Production Line

Commissioning Date: 2023 | Type: Building Materials Aggregate · Medium Sized Mine

Actual Output: 260 t/h | Maximum Feed Size: 680 mm | Equipment Cost Savings: Approx. 45%

Customer Feedback: “Replacing the original jaw crusher plus impact crusher setup with a single hammer crusher saved approximately 30% in civil engineering costs, shortened the production line by nearly half, and now requires only two operators per shift.” – Project Manager, Building Materials Aggregate Purchaser

Tanzania Dar es Salaam Cement Plant Raw Material Preparation

Commissioning Date: 2022 | Type: Cement Raw Materials · Large Scale Plant

Design Capacity: 300 t/h | Final Product Size: up to 30 mm | System Configuration: Automatic Lubrication

Customer Feedback: “In remote mining areas, our biggest fear is downtime caused by bearing failure due to grease shortages. Since implementing the automatic lubrication system, we’ve operated continuously for six months throughout the dry season with zero main bearing failures, significantly reducing our emergency repair costs.” – Equipment Manager, Cement Group

Hammer Crusher Technical Specifications

Model	Rotor dia.×length (mm)	Capacity (t/h)
DLPCZ1308	1310×790	100–160
DLPCZ1512	1500×1160	250–400
DLPCZ1615	1675×1510	400–800
DLPCZ1815	1776×1510	400–900

Hammer Crusher Frequently Asked Questions (FAQ)

Q1: Can this machine completely replace the combination of a jaw crusher and an impact crusher? What size of mines is it suitable for?

With a Mohs hardness of only 3, limestone is low in hardness and toughness, making it ideal for single-stage integrated crushing using a limestone hammer crusher in aggregate production lines. The three-chamber impact structure can directly crush raw stones measuring 600–700 mm down to the final product size, eliminating the need for intermediate transport. In completed projects, the single-unit output exceeds 100–300 t/h, making it suitable for small and medium-sized mines and aggregate production lines. By providing the feed size, output, and final product specifications, we can precisely match the appropriate model and compare the investment differences between the two solutions.

Q2: Do the hammer heads and liners wear out quickly? What is the replacement cycle?

Limestone has low hardness compared to granite and basalt. As a single-stage hammer crusher used in limestone quarries, the service life of the hammer heads can be extended by 40%–60% or more. Actual replacement intervals vary depending on fluctuations in soil content and particle size. However, during our on-site installation training, we demonstrate how to measure hammer thickness, assess liner wear, and adjust discharge gaps, enabling scheduled maintenance to prevent unplanned downtime.

Q3: Can you provide a complete limestone aggregate production line as a package?

Absolutely. As a direct manufacturer, after these mining hammer crushers achieve efficient primary crushing, we can also provide a full range of supporting equipment, including vibrating feeders, vibrating screens, belt conveyors, and baghouse dust collectors, along with complete line design plans, foundation drawings, and material balance sheets. The turnkey solution simplifies the procurement process and centralizes after-sales support. We can also provide layout plans based on site floor plans to lock in civil engineering costs in advance.

Click to Get a Limestone Crusher Selection Plan and Quote

Please provide the feed size, target output (t/h), and finished product specifications. We will provide model recommendations, motor power calculations, and foundation drawings within 24 hours. Our quotes are transparent and free of middlemen.

One year warranty on the whole machine | Lifetime technical support | On site installation and commissioning | Turnkey production line solutions