Custom Iron Ore Beneficiation Line

Project Overview

The DLHGC Horizontal Gyratory Crusher is an advanced primary crushing solution specifically engineered for iron ore processing. With a single-unit output ranging from 1400 to 3500 TPH and a discharge size of 200mm or less, it delivers the crushing performance that traditionally required a three-stage hard rock crushing process, now achievable in just two stages. The most significant engineering innovation lies in its reduced feeding height—approximately 50% to 60% lower than that of a traditional gyratory crusher—which directly translates into a 60% to 70% reduction in infrastructure construction costs including crusher foundation, feeding platform, and civil engineering works. Adopting a hoisting assembly structure, the DLHGC features a short installation period and high equipment capacity, making it the ideal primary crusher for large-scale iron ore mines seeking to minimize capital expenditure while maximizing throughput.

Process Flow

Run-of-mine iron ore is fed directly into the DLHGC Horizontal Gyratory Crusher, which performs high-capacity primary crushing with a discharge size controlled at 200mm or below. Thanks to this fine primary discharge specification, the traditional three-stage hard rock crushing process—typically comprising primary jaw crushing, secondary cone crushing, and tertiary fine crushing—can be simplified into a more efficient two-stage configuration. The primary crushed material is conveyed to the secondary crusher for further size reduction, followed by vibrating screen classification. Qualified aggregates of target specifications are directed to finished product stockpiles, while oversized materials are returned to the secondary crusher in a closed-circuit loop. The reduced feeding height of the DLHGC allows the entire primary crushing station to be built at a significantly lower elevation, cutting earthwork volume, concrete foundation scale, and steel structure requirements, thereby accelerating project construction timelines and reducing overall investment.

EPC Service Content

Zhongyu Dingli delivers a complete EPC turnkey solution for iron ore crushing projects, covering geological and ore body analysis, process design optimized for specific iron ore characteristics, equipment manufacturing and supply, civil engineering and infrastructure construction, installation and commissioning, operator training, and long-term after-sales support. The company provides customized crushing and processing solutions for a full spectrum of materials including iron ore, bluestone, limestone, basalt, granite, pebble, coal gangue, calcite, quartz stone, dolomite, barite, diabase, tuff, and high calcium limestone, as well as targeted processing for kaolin, industrial solid wastes such as slag and tailings, and construction and demolition waste. From individual standalone equipment to full turnkey production lines, and from fixed plant configurations to flexible mobile crawler unit solutions, all systems are integrated under a single contract ensuring schedule control, cost optimization, and consistent quality throughout the project lifecycle.

Project Cases and Data

• Processed Material: Iron ore
• Capacity Range: 1400-3500 TPH per single unit
• Discharge Size: ≤ 200mm
• Feeding Height Reduction: 50-60% lower than traditional gyratory crusher
• Infrastructure Cost Saving: 60-70% reduction compared to traditional gyratory crusher installation
• Process Simplification: Three-stage hard rock crushing reduced to two-stage, lowering overall project investment
• Assembly Design: Hoisting assembly structure enabling short installation period
• Maximum Single-Unit Output: Up to 3500 tons per hour

FAQ

Q1: How does the DLHGC Horizontal Gyratory Crusher reduce infrastructure costs by 60-70%?

The DLHGC features a feeding height approximately 50-60% lower than traditional gyratory crushers, which directly reduces the scale of crusher foundations, feeding platforms, and supporting steel structures. Less earthwork excavation, smaller concrete pours, and lighter structural steel requirements collectively cut infrastructure construction costs by 60-70%, making it especially advantageous for greenfield mine projects with tight capital budgets.

Q2: Why can the DLHGC simplify a three-stage crushing process into two stages for iron ore?

The DLHGC delivers a primary discharge size of 200mm or less, which is fine enough to feed directly into a secondary cone crusher without requiring an intermediate crushing stage. In conventional iron ore processing, primary jaw crushers typically produce discharge sizes of 300-350mm, necessitating three stages to reach final product specifications. By eliminating one crushing stage, the DLHGC reduces the number of crushers, conveyors, and screening circuits required, significantly lowering overall project investment and operational complexity.

Q3: What is the advantage of the hoisting assembly structure in the DLHGC?

The hoisting assembly structure allows major crusher components to be pre-assembled and lifted into position as integrated modules, rather than being assembled piece by piece on site. This design shortens installation time, simplifies maintenance access for component replacement, and enables rapid commissioning. Combined with the reduced foundation requirements, the DLHGC can be brought into operation significantly faster than traditional gyratory crushers, reducing project lead times and accelerating return on investment for iron ore mining operations.