There are numerous difficulties for operators in the field of manufactured sand making, construction waste recycling, and mining tailings processing. At present, quite a lot of small and medium-sized mobile sand making projects are still using the stationary double roller crushers which require considerable capital investment in building concrete foundations in the initial stage of construction. When the project ends or the location of operation changes, the equipment will not work anymore. And the foundation needs to be rebuilt in order to move the equipment elsewhere, which will lead to unnecessary cost of both capital investment and construction. Usually, for the split crushing and conveying system in the market, operators will need to dismantle the conveyor belt, dismantle the main part of the crushing machine, and then move the equipment with cranes. It takes several days to reassemble the equipment after relocation, which affects the schedule of production.
What’s worse, many diesel-powered mobile crushing machines consume too much fuel every day. Its exhaust gas emission and pollution increase the difficulty of meeting environmental inspections and make construction projects often stop or correct themselves. And many of the existing mobile crushing machines are used in the field of primary and secondary crushing operations. Thus, it is difficult for operators to continuously make qualified 0-5mm manufactured sand that meets the standard of commercial concrete. The resulting aggregate has uneven gradation and weak market competitiveness. The equipment only controlled by mechanical discharge gap adjustment may have instability in particle size because of its processing of raw materials with different hardness or reinforced concrete block. Thus, it is necessary for operators to shut down the machine for manual adjustment, which leads to low production efficiency. Moreover, in the outdoor crushing environment, the machine is often exposed to heavy dust, rain water, and acid or alkali corrosion. The conventional equipment coating will be rusted easily, leading to faster aging of the frame and components, thus increasing the maintenance cost.
In order to solve the above production difficulties, MP has developed the MP MW110DRC Wheeled Mobile Double Roller Crusher Plant. Based on the fine crushing technology of double roller crusher, the integrated mobile crushing system makes breakthrough in many aspects, such as transportation flexibility, energy consumption, product quality, and equipment wear resistance.
MP MW110DRC Wheeled Mobile Double Roller Crusher Plant is in the category of the MP Series Mobile Crushing & Screening Equipment. The entire machine integrates DRC110 double roller crusher as the main crushing equipment, and includes feeding conveyor and discharge conveyor all mounted on a single wheeled chassis. The entire system uses electric driving mode. According to actual conditions of the construction site, the hydraulic supporting leg can be chosen. Without concrete foundations, the equipment can be towed to the work site directly and be leveled and put into production shortly.
The equipment is specially designed for mobile fine crushing and manufactured sand production. 0-30mm medium-size feed materials can be crushed into 0-5mm finished products by the equipment, suitable for short-period construction sites, distributed construction projects, and mobile crushing projects in multiple locations.
When producing manufactured sand from river pebbles, limestone, weathered rock, and other materials on the construction site, this equipment is suitable for small and medium-sized sand making projects with short construction periods and changing locations. Permanent factory building and production line are not required. The materials can be crushed and transported directly on the construction site and sold after production.
The concrete waste and brick materials produced by demolishing of urban and road renovation projects can be crushed directly on the construction site. Construction waste can be transformed into high-quality recycled aggregate by the equipment and reduce the transportation cost of waste and realize resource utilization.
The mining tailings and quarry waste materials can be processed further and become the valuable manufactured sand and construction filling material. By transforming the previously worthless waste materials into products that can be sold, the equipment can help increase economic benefit of mining business.
The wheeled integrated structure makes it unnecessary to disassemble the equipment when moving. The towing vehicle can tow the whole machine to another work location directly without foundation construction, crane lifting, equipment assembly, and secondary installation. Thus, the equipment can be used in multiple projects and greatly increase utilization rate.
The entire machine uses electric driving technology without direct exhaust emission. It is able to operate in the area with strict environmental protection requirements efficiently, and reduce fuel consumption greatly compared to the diesel-powered mobile crushing equipment. Continuous long-term operation is benefited from greatly reduced operation cost.
With specialized double roller fine crushing technology, the equipment produces stable 0-5mm manufactured sand with uniform particle gradation and fine particle shape. Comparing with the conventional coarse crushing equipment, the products have increased commercial value and strong market competitiveness.
The hydraulic and mechanical dual discharge gap adjustment system realizes flexible adjustment according to different hardness of the materials. Thus, the shutdown frequency due to adjustment decreases and increases the production continuity. The entire machine has been applied the technology of anti-corrosion coating and highly-protected motor, which can ensure excellent wear resistance in harsh outdoor environment and reduce maintenance cost.
Feeding system, crushing equipment, and discharge conveyor have been factory-integrated to form one mobile system. With optional hydraulic supporting leg, the machine can quickly realize stable positioning after arriving at the site. After connecting electricity, production can start immediately.
The MP MW110DRC Wheeled Mobile Double Roller Crusher Plant is especially designed to meet all demands of mobile fine crushing and manufactured sand production. Through the combination of mobile chassis, fine crushing unit, full electrical drive system, dual adjustment system, and anti-corrosion protection system, the equipment owns seven major differentiated advantages, which balance production efficiency, operating cost, and service life.
The whole machine is equipped with a specially designed double roller crushing system.The finished product size can be always controlled within the range of 0-5mm. Different from the existing mobile crushing equipment that only concentrates on the primary and secondary crushing, this machine uses the crushing technology based on extrusion and produces manufactured sand with a good particle shape and less elongated and flaky particles.The crushed material can meet the demands of commercial concrete and road base material well, providing strong market competitiveness and high added value of the product.
The crushing unit is equipped with two 110kW motors working in parallel.The total power of the crushing drive system reaches 220kW. Combined with the large diameter of rollers, the machine provides a bigger contact area of the material, ensuring efficient compression and crushing performance.The single machine has a constant processing capacity of 80-120tph, which enables continuous high-load operation of small and medium mobile sand production project.
The equipment is provided with the two-axle wheeled chassis equipped with eight 12R22.5 heavy duty engineering tires.Under the standard towing vehicle, the whole machine can be transported on road without disassembling and large cranes.For projects with many operating locations, transportation time can be shortened to just several hours, avoiding long-term production interruptions and improving the equipment utilization.
All operating units of the machine are driven by electric motors.Different from the diesel-driven mobile crushing equipment, there is no direct exhaust emission, which makes the operation possible under the environmentally-sensitive areas such as urban construction site and mines with strict environmental regulation.Power consumption of the electric machine is much lower than fuel consumption, which can help to reduce the production cost continuously for operators.
Hydraulic support legs are offered as an optional configuration.Together with the independent 4kW drive motor, the hydraulic supporting system can automatically lift and lower the machine body after transportation and level the equipment rapidly.In contrast to the conventional method of wood block positioning or temporary supporting, hydraulic supporting legs make the machine keep stable positioning even on uneven ground.This can eliminate the machine vibration in the operation and shorten the preparation time before production.
The crusher discharge gap is provided with two adjustment systems.The hydraulic adjusting system allows the quick and stepless adjusting of the discharge size, which can help operators to adapt to changes of hardness of raw material quickly.The mechanical locking system ensures the fixed production gap in the long-term operation, maintaining the consistency of finished product size.Depending on the different raw material and demand of finished sand, operators can choose different adjustment modes flexibly, making one machine suitable for multi-production situations.
The whole machine is equipped with a multi-layer Nippon industrial coating system.Before painting, the steel structure undergoes the shot-blasting and high-pressure cleaning treatment for complete rust removing.Coating system includes:One layer of epoxy zinc phosphate primer;One layer of epoxy micaceous iron oxide intermediate coating;Two layers of polyurethane top coating.This four-layer coating can isolate the dust, rainwater, and corrosion of acid/alkali effectively.Under harsh operating condition such as construction waste recycling site and mining site, the speed of corrosion of the frame structure is greatly decreased.This can minimize the costs of future refurbishment, repainting, and parts replacement and prolong the life span of the whole equipment.
The crushing main unit is the core processing unit of the whole mobile plant.Its roller specifications, drive power, feeding/discharge size range and processing capacity directly affect the manufactured sand production efficiency and finished product quality.All parameters are verified under the long-term heavy-duty operating condition, ensuring steady operation under the fine crushing.
Item | Standard Specification |
Crusher Model | DRC110 |
Maximum Feed Size | 30 mm |
Finished Product Size Distribution | 0-5 mm |
Standard Processing Capacity | 80-120 tph |
Main Unit Weight (without hydraulic oil station) | 25,000 kg |
Overall Dimensions (L×W×H) | 5310×2130×1850 mm |
Roller Size (Diameter×Length) | Φ1100×1000 mm |
Rated Roller Speed | 67 r/min |
Crushing Drive Motor Power | 110 kW×2 = 220 kW |
Motor Model | YE2-315L1-6 380V |
Motor Insulation Class | Class F |
Motor Protection Rating | IP55 (dust-proof and water spray-proof) |
Detailed Parameter Explanation
The combination of the maximum feed size of 30mm and the steady discharge size of 0-5mm allows the equipment to process the semi-finished materials from previous crushing stage directly and produce the finished manufactured sand by one-time crushing process.It reduces the demand for secondary crushing and screening, simplifying the whole production line.The combination of the large diameter and length of rollers of Φ1100×1000mm and the slow rotation speed of 67r/min gives a bigger contact area and more complete compression crushing.The slower roller speed decreases the wear of the roller surface caused by the impact effect and extends the replacement cycle of wear-resistant roller shell, reducing the cost of consumable.
The two 110kW motors provide the total crushing power of 220kW.With the production capacity of 80-120tph, the equipment is suitable for most of the small and medium mobile manufactured sand projects.Even under the situation of processing the relatively hard material, the system keeps enough power reserve and avoids the problem such as lacking of crushing force and frequent blockage.The YE2 six-pole industrial motors are featured by Class F insulation, which allows them to resist the high temperature.With the IP55 protection rating, the motors can resist the dust and water spray, suitable for the outdoors working environment with lots of dust and high humidity.
The weight of the main unit is 25,000kg and its compact dimensions are 5310×2130×1850mm.The highly integrated crushing structure reduces the space occupying on the mobile chassis while keeping enough space for side conveyors and hydraulic oil station installation.The crusher is delivered with the pre-installed main frame, sliding frame, rollers, hopper, drive motors and adjustment cylinders.After delivery, the customer does not need complicated installation on-site and can test and operate the equipment immediately after power supply connection.
The hydraulic system is responsible for dynamic adjustment of discharge clearance, and the lubrication system provides lubricating oil constantly to roller bearings and transmission friction points.Both systems are independently calculated with pressure and flow regulation, which guarantees stable work without interfering with each other and provides full security for permanent work of the crushing unit.
Item of System | Parameter Specification |
Flow rate of Hydraulic oil | 7 L/min |
Drive power of Hydraulic station | 5 kW |
Rated working pressure of Hydraulic system | 8 MPa (Peak pressure ≤16 MPa) |
Maximum protection pressure of Hydraulic system | 20 MPa |
Method of discharge clearance adjustment | Hydraulic adjustment + Mechanical adjustment |
Flow rate of lubrication oil | 14 L/min |
Rated working pressure of lubrication system | <1.5 MPa |
Drive motor power of lubrication pump | 1.5 kW |
Detailed parameter explanation
The hydraulic system is calculated with rated working pressure 8MPa, peak pressure 16MPa, and maximum overpressure protection 20MPa.In case any uncrushable object like steel bar and metal block accidentally goes into the crushing chamber, system will automatically release pressure and give buffering protection.This will avoid too large impact force damaging rollers, chassis frame, and other important components.The hydraulic system provides flow rate 7L/min and is driven by 5kW small size drive motor.The system is responding quickly to discharge clearance adjusting, and low power consumption avoids the increase of operation cost.
The lubrication system uses high flow oil supply with 14L/min.The working pressure is lower than 1.5MPa, and the low-pressure high flow lubrication method provides oil distribution equally to all friction parts of bearing.The system takes away heat generated in the work of bearings, thus avoids dry run, overheating, seizing and other faults caused by shortage of lubrication oil.Combination of hydraulic adjustment and mechanical lock combines flexibility of hydraulic fine adjustment and stability of mechanical fixing.This helps operators quickly change different specifications of manufactured sand in case of long term work and keep product size constant.Thus, the equipment is suitable for multi-material and multi-order production needs.
The feeding and discharge conveyors are completely integrated into the mobile chassis construction.There is no necessity of any conveyor support structure.The whole feeding and discharge process moves together with chassis, thus there is no need of additional conveyor dismantling during transportation.
Feeding and Discharge Conveyor Unit | Specification |
Feeding conveyor | B1000-6m, equipped with 11kW drive motor |
Discharge conveyor | B1000-9m, equipped with 11kW drive motor |
Detailed parameter explanation
Both conveyors use standard B1000 belt width design, which gives enough conveying capacity and avoids material spillage and blockage.The 6-meter feeding conveyor fits the requirements of loading height of loaders and excavators.Materials can be fed smoothly and evenly into crushing chamber, and sudden material surge, which causes overload of crusher, can be avoided.The 9-meter long discharge conveyor allows conveying of manufactured sand to farther place of stockpile.Thus there will be enough space for operation of equipment and frequency of machine moving because of lack of place of stockpile will be reduced.Each conveyor is equipped with independent drive motor of 11kW, which gives enough power for full loading operation.The belt system moves stably without slip or jam, thus some common problems like belt deviation and belt tear will be avoided.
The equipment gives separately standard parameters for transportation mode and working mode.The transportation dimensions are calculated according to road transportation requirements.The total installed power takes into account crushing unit, conveyor systems, hydraulic system and lubrication system and accurately reflects real requirements of power supply on the site of operation.
Item of Equipment | Parameter |
Dimensions in working position (Length × Width × Height) | 16000 × 4900 × 4700 mm |
Dimensions in transportation position (Length × Width × Height) | 14000 × 2400 × 4700 mm |
Total machine weight | 42,500 kg |
Total installed power | 255 kW |
Detailed parameter explanation
The transportation width is 2400mm and satisfies standard road transportation width requirements.There is no need of complex oversized transportation procedure in most transportation cases, thus long distance relocating will be easier.In operational position, the working width reaches 4900mm, giving enough spacing between feeding, crushing and discharge zones.This will create convenient operating environment for checking, maintenance and cleaning.The total machine weight is 42,500kg.The weight distribution is optimized for two-axle chassis, and ensures reliable towing and avoiding imbalance during transportation.The total installed power is 255kW.Using this value customers can calculate transformers and power cables and prepare the infrastructure of power supply correctly before installation, avoiding limitations of production because of insufficient power supply.
The chassis carries all the weight of the machine. The tire configuration is made for heavy-duty transportation, and hydraulic support legs are optional component for increasing the stability of the machine during operation.
Chassis Item Configuration
Chassis construction | Two-axle wheeled chassis |
Tire specification 12R22.5 | total 8 tires |
Optional hydraulic support leg drive power | 4 kW |
Detailed parameter explanation
The two-axle chassis is provided with eight 12R22.5 heavy duty engineering tires.Multiple tires load distribution gives increased carrying capacity and reduces the stress of the single tires.During heavy load transportation on the uneven road, the probability of tire damage is significantly decreased.The optional hydraulic support legs are driven by 4kW drive motor and have quick lifting and leveling abilities.On uneven outdoor operational sites, the support system will quickly level the machine.Isolating vibrations caused by tire deformation, the hydraulic support system increases the stability of crushing and reduces fatigue of the components because of continuous vibrations.
During operation, 0-30mm raw materials will enter the integrated vehicle-mounted hopper.Then, the materials will be smoothly conveyed into the crushing chamber of the DRC110 double roller crusher through the B1000-6m feeding conveyor.The two rollers of the crusher will rotate in the opposite direction at a standard rotating speed of 67r/min.Under the effect of the extrusion force between the roller surfaces, the materials will be compressed and finely crushed.The operators can adjust the roller gap through the hydraulic and mechanical dual adjustment system to control the particle size of the manufactured sand.The processed 0-5mm manufactured sand will be conveyed from the bottom outlet of the crusher through the B1000-9m discharge conveyor for a long-distance storage.All the operations from the feeding of raw materials to the manufacture of sands are integrated into one piece of crushing operation.The crushing unit, conveying system, hydraulic system, and lubrication system are integrated into the central electrical control system.
The complete machine adopts centralized electric control, which facilitates the control over the start/stop of equipment operation, conveyor, and hydraulic discharge gap adjustment.After the optional deployment of hydraulic support legs, the machine will achieve stable support on the ground.The vibration of the machine caused by the elasticity of the tires is greatly reduced by the system, which provides stable manufactured sand production and reduces the structural fatigue and wear of the components caused by the vibration.
The MP MW110DRC Wheeled Mobile Double Roller Crusher Plant makes great progress over the constraints of the traditional stationary crushing equipment.With the wheeled integrated structure, the machine resolves the problem of the difficulty of relocation of the equipment between multiple sites.The fully electric drive system decreases the cost of long-term operations and environmental compliance.The special double roller fine crushing technology guarantees stable production of the valuable manufactured sands.The dual discharge adjustment system realizes the flexible adaptation to different raw material situations.The multi-layer anti-corrosion technology increases the service life of the equipment in harsh environments.
With one machine, the application of the machine is very flexible in three main applications:Mobile manufacture of sand.Construction waste recycling.Mining tailings processing.Thus, it is not necessary to purchase multiple pieces of equipment and improves the equipment versatility and utilization.By decreasing the cost in infrastructure construction, transportation, energy consumption, spare parts replacement and increasing the value of the finished products, the equipment will create continuous economic benefits for the customers.It is the ideal piece of complete equipment for short-term and mobile fine crushing and manufactured sand production projects.
FAQ1: Is this mobile double roller crushing plant only suitable for the manufacture of sand? Can it process construction waste and mining tailings?
No. The equipment is not only used for the manufacture of the natural stone sand.With the feed size of 0-30mm, the equipment is capable of processing the construction waste concrete fragments, mining tailings and quarry waste materials.With the double roller extrusion fine crushing technology, the equipment can continuously process the different types of materials into 0-5mm recycled aggregates or filling materials.One piece of equipment can flexibly transfer to the sand production plants, demolition sites and mining tailings processing sites, improving the equipment utilization and returns.
FAQ2: What size of the transformer should be configured on the site when the total installed power of the equipment is 255kW?
It is recommended to configure the transformer of 315kW or more to have enough power reserve.Otherwise, the unstable voltage will be caused by the high load and hard raw materials.The equipment is driven by the standard industrial motors of 380V.It is only necessary to provide the standard industrial power cable to connect the main electrical control cabinet, which doesn't need any special power modification.In case of the temporary insufficient power capacity, it is possible to control the loading of the equipment by controlling the feeding rate.
FAQ3: Can the machine work without the optional hydraulic support legs?
Yes.The hydraulic support legs are optional accessories of the machine and are not necessary for the normal operation.Without the support legs, the machine will use the tires for the support while operating.It is suitable for the flat operation area and the short-term operation project with limited operating hours per day.In case of long-term continuous operation over 8 hours a day and the operation in the uneven outdoor site, it is better to use the support legs to avoid tire vibration and reduce the resonance damage to the frame and rollers and increase the service life of the wear parts.
FAQ4: With the transportation width of 2.4 meters, does the equipment need oversized transportation approval?
The transportation width of the complete machine is 2400mm, which is in line with the standard road transportation width requirement in most regions.It is possible to use a conventional towing vehicle to transport the equipment without the procedure of the oversized transportation approval.This reduces the waiting time caused by the transportation approval process.
FAQ5: Can the discharge size be adjusted below 0-5mm or larger aggregate size?
The standard finished product size range is 0-5mm.The hydraulic and mechanical dual adjustment system allows the precise adjustment within this range.In case of larger than 5mm aggregates, the discharge gap should be increased correspondingly.But the operation outside the designed range may influence the productivity and particle shape quality.This machine is designed for fine crushing and the manufacture of sands.For long-term production of the aggregates larger than 5mm, it is better to use the dedicated secondary crushing mobile equipment.
FAQ6: How often should the roller wear parts be replaced? Is it complicated to do routine maintenance?
The replacement period depends on the hardness of the raw material. In case of the softer materials, like limestone and weathered rock, the roller shell replacement period is normally 8,000-12,000 tons.In case of harder materials, like concrete and granite, the replacement period is approximately 5,000-7,000 tons. The complete machine is equipped with the independent automatic lubrication system, which will grease according to the pre-set periods and doesn't require the regular greasing. Maintenance points of the frame and conveyor system are properly designed.The routine inspection and replacement of the wear parts can be done by one operator.
FAQ7: The machine uses full electric drive. How can it work at outdoor site without grid power?
For the outdoor site where there is no fixed grid power supply, a diesel generator set can be used as the power supply source. The generator set of 315kW or more is recommended to guarantee the full load operation of the complete machine. Compared to the integrated diesel powered mobile crushing equipment, the generator is only used as the external power supply source. When the grid electricity becomes available, the equipment can be switched to the grid power supply mode.In comparison to fuel-based machinery, this approach offers reduced energy expenses in the long run, as well as reduced emissions and improved environmental performance.MP MW110DRC Wheeled Mobile Double Roller Crusher Plant offers a comprehensive solution that integrates mobile design, energy efficiency, environmental safety, and stability of finished product quality into a single crushing machine.
Wherever your worksite is located, whatever your equipment specifications require, and no matter how severe the operating conditions — MP Crusher delivers the equipment, the solution, and the performance you need. Our equipment is already at work in more than 20 countries around the world.
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