120TPH PCZ Heavy Hammer Crusher for Coal Gangue Processing in Turkey

Project Background

Anadolu Cimento ve Insaat A.S., a Turkish construction materials company with operations in the Zonguldak coal mining region, identified an opportunity to process coal gangue -- a solid waste product from nearby coal mines -- into lightweight aggregate and supplementary cementitious material. The company's production manager, Mr. Mehmet Yilmaz, began researching heavy hammer crushers suitable for coal gangue in early 2023. He conducted a targeted search on Google for "heavy hammer crusher for coal gangue" and found Xianglong Machinery's website, which featured a dedicated product page for the PCZ Heavy Hammer Crusher with detailed specifications and application case studies. He also found XLM's profile on Alibaba International Station and submitted inquiries through both channels.

Channel Communication and Needs Assessment

XLM's sales engineer, Ms. Jenny Zhao, responded to both inquiries within 3 hours and arranged a WhatsApp consultation with Mr. Yilmaz and XLM's application engineer, Mr. David Chen. The coal gangue had a compressive strength of 40-80 MPa, a feed size of up to 600 mm, and a moisture content of approximately 8-12%. The target output was 0-30 mm crushed gangue at 120TPH for use as lightweight aggregate in hollow blocks and as a raw material for clinker production at a nearby cement plant.

Technical Solution and Engineering Alignment

David recommended the PCZ-1820 Heavy Hammer Crusher, which offered a large feed opening suitable for the irregular-shaped gangue lumps and a high reduction ratio enabling single-stage crushing from 600 mm to minus 30 mm. The PCZ's heavy-duty rotor and replaceable hammer design were highlighted as key advantages for the abrasive coal gangue material, minimising downtime for wear-part replacement. The system also included a ZSW-490x110 Vibrating Feeder with a grizzly to remove minus 30 mm fines before crushing, a 3YK1860 Circular Vibrating Screen for product classification, and a Belt Conveyor system for product stockpiling.

Technical discussions proceeded over two weeks via WhatsApp and email. David provided detailed wear-part consumption estimates and a maintenance schedule. Critical safety systems were engineered for coal gangue processing: explosion-proof electrical components (ATEX Zone 22 certification for combustible dust), integrated dust suppression spray systems at transfer points, dust concentration monitoring sensors with automatic alarm shutdown, and spark detection systems on the belt conveyor. For the Black Sea region's high rainfall and the material's 8-12% moisture content, the PCZ-1820 was equipped with: pre-screening grizzly to remove wet fines and reduce clogging, enlarged discharge openings to prevent material buildup, and wear-resistant scraper bars on the hammer rotor for self-cleaning action. The contract was signed in March 2023, with a delivery period of 55 days.

Delivery, Installation, and Commissioning

Equipment was shipped from Qingdao to Istanbul port and transported by road to the Zonguldak site. XLM provided remote commissioning support via WhatsApp video call, with engineer Mr. David Chen guiding the local crew through a 7-day commissioning process. The PCZ-1820 achieved 128TPH at minus 30 mm during the acceptance test, exceeding the guaranteed capacity.

Results and Client Feedback

Within six weeks of commissioning, Anadolu Cimento was processing 900 tonnes of coal gangue per day, generating revenue from both lightweight aggregate sales and gate fees for gangue disposal. Mr. Mehmet Yilmaz stated: "The PCZ Heavy Hammer Crusher from XLM has been a perfect solution for our coal gangue processing project. Single-stage crushing from large feed to minus 30 mm has greatly simplified our process and reduced capital cost. The wear life of the hammers has exceeded our expectations. We are evaluating XLM's Double-stage Crusher for a second gangue processing line at our Karabuk facility."