Zenith MTW175G Trapezium Mill Powers Limestone Processing in Uruguay
Client Overview
A leading building materials producer in Uruguay sought to upgrade its limestone processing line to meet growing market demand for high-purity calcium carbonate powder (120-150 mesh, D80). Key requirements included:
- Stable output of 20-25 TPH
- Energy-efficient operation under high humidity conditions
- Compliance with EU-equivalent environmental standards
Challenge
The client’s existing Raymond mill struggled with:
❌ Frequent wear part replacements (2-week cycle for grinding rolls)
❌ Inconsistent particle distribution (D80 fluctuation >15%)
❌ Excessive dust emissions (35mg/m³)
Zenith Solution
After analyzing ore characteristics and operational data, Zenith recommended the MTW175G Trapezium Mill with customized configurations:
Technical Highlights
| Parameter | MTW175G Advantage |
|---|---|
| Grinding Efficiency | 22.5 TPH output (18% above industry avg. for 150-mesh limestone) |
| Wear Resistance | Curved shovel + 16MnCr5 alloy rollers extended maintenance cycle to 1,800hrs |
| Precision Control | PLC-integrated classifier maintained D80 stability (±3%) |
| Eco-Performance | Pulse dust collector achieved <10mg/m³ emission |
Installed System
- Main equipment: MTW175G Mill (185kW main motor)
- Auxiliaries:
• GZ4F vibrating feeder (0.45kW)
• 200kW centrifugal fan
• 22kW turbo classifier - Automation: Siemens S7-1200 PLC with HMI
Operational Results
✅ Throughput: Achieved 23.8 TPH consistently (4% above target)
✅ Energy Savings: 31.5kWh/ton vs. previous 48kWh/ton (34.4% reduction)
✅ Product Quality: 98.2% of particles within 120-150 mesh range
✅ Environmental Impact: Noise level maintained at 72dB(A); zero dust leakage
Client Testimonial
“Zenith’s MTW mill transformed our productivity. The modular design allowed rapid part replacement during planned maintenance – what took 8 hours now takes 2.5. Their remote monitoring system has prevented 3 potential breakdowns in 6 months.”
— Plant Manager, Uruguay Calcium Carbonate Co.
Why MTW Series Stands Out
- Arc Air Channel – Reduced airflow resistance by 19% vs conventional designs
- Conical Gear Drive – 98% transmission efficiency with 40% smaller footprint
- Dual-service Platform – Enabled simultaneous roller and classifier maintenance
