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Differences Between Impact Sand Makers and Roller Sand Makers
The core differences between impact sand makers and roller sand makers lie in four dimensions: working principle, finished product quality, applicable scenarios, and energy consumption & cost. Selection should be targeted based on material characteristics, finished product requirements, and production capacity needs.
I. Core Differences: Comprehensive Comparison from Principle to Application
| Comparison Dimension | Impact Sand Maker | Roller Sand Maker |
|---|---|---|
| Core Working Principle | Dual functions of "impact crushing + shaping": The impeller (linear speed 50-80m/s) rotates at high speed to drive materials, achieving crushing through "stone-on-stone" (material collision) or "stone-on-iron" (material impacting metal liners) modes, while optimizing particle shape. | Single function of "extrusion crushing": Two counter-rotating rollers crush materials using the extrusion force between them, with no additional shaping effect. |
| Finished Product Quality | 1. Particle shape: Cubic, needle-flake content ≤8%, continuous gradation, meeting GB/T 14684-2022 standard for construction sand. 2. Particle size: Stable production of sand with specifications like 0-5mm and 5-10mm, wide adjustable range of fineness modulus (2.3-3.2). |
1. Particle shape: Mostly irregular flake or powder, high needle-flake content (15%-25%), easy to have gradation gaps. 2. Particle size: More suitable for producing fine powder below 5mm; poor particle shape for coarse sand (5-20mm). |
| Applicable Materials | Suitable for medium-high hardness materials (Mohs hardness 5-8), such as granite, cobblestones, and basalt; also can process soft materials like limestone. | Only suitable for medium-low hardness materials (Mohs hardness ≤5), such as limestone, gangue, and gypsum; high-hardness materials cause severe wear to roller skins. |
| Processing Efficiency | Wide capacity range (10-500t/h), high crushing efficiency; "stone-on-stone" mode reduces equipment wear, enabling long continuous operation time. | Medium capacity range (5-200t/h); extrusion crushing is prone to jamming due to material adhesion or hard impurities, requiring frequent shutdowns for cleaning, resulting in weak continuous operation. |
| Energy Consumption & Cost | 1. Energy consumption: High unit energy consumption (8-12kW·h/t) due to high-speed impeller operation requiring high-power motors. 2. Maintenance cost: Wear parts (impellers, surrounding liners) need regular replacement, high single replacement cost but long replacement cycle (3-6 months). |
1. Energy consumption: Low unit energy consumption (3-6kW·h/t); extrusion crushing does not require high-speed operation, so motor power is small. 2. Maintenance cost: Roller skins wear quickly (need replacement every 1-2 months), low single replacement cost but high accumulated cost due to frequent replacements. |
| Environmental Performance | High dust generation, requiring matching high-power pulse dust collectors (air handling capacity ≥5000m³/h), noise around 85-95dB. | Low dust generation (no material splashing in extrusion crushing), low noise (70-80dB), low environmental investment cost. |
II. Selection Decision: 3 Steps to Determine the Suitable Model
1. Check Material Hardness and Finished Product Requirements
- If processing high-hardness materials (e.g., cobblestones, granite) and requiring high-quality machine-made sand (e.g., for mixing stations, prefabricated components), prioritize impact sand makers.
- If processing soft materials (e.g., limestone, gangue) and the finished products are only used in scenarios with low particle shape requirements (e.g., subgrade filling, brick factory raw materials), roller sand makers are optional.
2. Check Production Capacity and Budget
- Medium-large production lines (capacity over 50t/h): Impact sand makers match the capacity better; although the initial investment is high (about 300,000-1,000,000 RMB/unit), the long-term production efficiency and finished product value are higher.
- Small production lines (capacity 5-50t/h): Roller sand makers have low initial investment (about 100,000-300,000 RMB/unit), suitable for scenarios with limited budget, short-term production, or intermittent operation.
3. Check Site and Environmental Conditions
- If the site is near residential areas (sensitive to noise and dust): The low-noise and low-dust advantages of roller sand makers are more obvious, which can reduce environmental rectification costs.
- If the site is far from residential areas and can be equipped with a complete dust removal system: The capacity and finished product advantages of impact sand makers can be fully utilized.
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