The structural types of double-roll crushers (also known as twin-roll crushers) can be classified into various categories based on dimensions such as the number of rolls, roll surface shape, adjustment method, transmission form, and application scenarios. The specific classifications and technical characteristics are as follows: 1、 Classification by number of rolls 1. Double-roll crusher (standard type) Structural features: Consists of two parallel rollers, one fixed roller and one movable roller. The movable roller is supported by springs or a hydraulic system and can move horizontally to adjust the gap and provide overload protection. Application scenarios: Medium and fine crushing operations, processing medium to low hardness materials such as coal, limestone, and coke (compressive strength ≤ 300 MPa), with adjustable output particle size ranging from 1–20 mm. Representative models: 2PG—400×250, 2PG—750×500 (processing capacity 5–55 t/h). 2. Four-roll crusher Structural features: Composed of two sets of rollers in series to achieve two-stage crushing. Features hydraulic gap adjustment and a centralized lubrication system, with optimized tooth design to enhance crushing efficiency. Application scenarios: Fuel preparation for circulating fluidized bed boilers (e.g., coal gangue), capable of replacing a secondary crushing system to reduce equipment investment. Advantages: High crushing ratio (10–15), low over-crushing rate, suitable…
Volcanic rock is difficult to crush due to its high hardness (Mohs hardness), high silicon content and easy to wear the equipment when crushing, traditional crushing equipment is easy to wear and low efficiency. With its unique design and technical advantages, Roll Crusher becomes the ideal choice for processing volcanic rock. 1. Roll Crusher High Efficiency Crushing and Particle Size Control Squeeze and Shear Dual Action Double rolls rotate relative to each other to generate high pressure squeeze and shear force. Which can quickly crush large volcanic rock and avoid clogging problem. Precise particle size adjustment Hydraulic system adjusts the roll spacing (usually 1-5mm adjustable), the discharged particle size is uniform. To meet the fine demand of construction aggregate or mechanism sand. Deep V-shape crushing chamber design Dead zone-free structure improves the material passing rate and adapts to the high hardness characteristics of volcanic rock. 2. Volcanic rock crushing abrasion resistance and durability High wear-resistant materials The rolls are made of high manganese alloy or thickened manganese steel (e.g. 20cm thick), which improves the wear-resistant life by more than 3 times and reduces the frequency of replacement (3 years free replacement for some models). Overload protection mechanism Spring or hydraulic…
What is a roller crusher? Roller crusher (also known as double-roller crusher, roller sand making machine) is a kind of mechanical equipment to achieve crushing through two oppositely rotating rollers to squeeze the material, mainly used for medium and fine crushing of medium-hardness materials (such as limestone, coal, pebbles, etc.), is widely used in the cement, metallurgy, chemical industry, electric power and building materials and other industries. 1. Core structure and working principle Basic structure Roller: the core working part, divided into fixed rollers and movable rollers, the surface can be designed as smooth or toothed (toothed roll crusher), the material should be wear-resistant. Adjustment device: Adjust the gap between the two rolls (0.5-50 mm) by wedge or shim to control the granularity of the material (e.g. if the wedge is moved up and the gap is increased, the material will become coarser). Driving system: double motor drive, through the triangle belt to drive the roller reverse rotation, some models are equipped with hydraulic spring overload protection device. Auxiliary components: support bearings, safety cover, iron removal device (to prevent damage to the roller by metal foreign objects). Working Principle The material falls into between the two rollers from the inlet,…
Roll Crusher High Humidity Material Solution Roll crusher is prone to sticking rollers, clogging, uneven discharging and other problems when dealing with viscous materials (such as clay, wet coal) or materials with high moisture content (moisture content >15%). The following are the specific operation techniques and optimisation solutions combined with industry practice: 1. Pre-treatment and feed control Moisture regulation and control Drying pre-treatment: For materials with moisture content > 20%, priority is given to drying equipment (such as drum dryer) to reduce the humidity to less than 15%. Mixing of wet and dry materials: Mix wet materials with dry materials (e.g. dry coal, limestone) in the ratio of 1:1~1:2 to reduce the overall viscosity. Heating assistance: add hot air device (temperature 80~120℃) at the feeding port to evaporate the surface moisture and reduce the adhesion. Optimisation of particle size and feed Pre-screening: Pre-screen the large materials (>300mm) to avoid jamming or roller gap extrusion splash. Uniform feeding: adopt frequency conversion feeder to control the flow rate, avoid instantaneous overloading and blockage (suggested feeding speed ≤ 80% of the rated value). 2. Equipment parameter adjustment Roll gap and pressure adjustment Expand the roller gap: for high viscous materials (such as plasticity…
Roll Crusher Application Scope Roll Crusher (alias: Double Roll Crusher, Roll Crusher) is a compact, reliable, cost-effective crushing equipment used in many industrial fields. A roll crusher squeezes material with two rotating rollers, which are either smooth (for hard materials) or toothed (for brittle materials). The following are the main applications and scenarios of roll crusher: 1.Industry Application Scope Coal industry Direct crushing of raw coal: No need to remove gangue in advance, only need to remove iron, remove impurities can be crushed, simplify the coal selection process, reduce investment costs. Advantage: uniform particle size of the crushed material, low over-crushing rate, suitable for large coal mines or coal processing plants. Mining and metallurgy industry Ore crushing: fine crushing of iron ore, quartzite and other minerals of medium hardness (compressive strength ≤ 160MPa). Refractory and building materials: processing cement raw materials, limestone, refractory clay, etc., for coarse and medium crushing process. Building materials and environmental protection Artificial sand production: Making sand from pebbles, construction waste and other stones, with a finished size of 50μm-20mm. Ceramic industry: crushing kaolin and other raw materials to meet the requirements of fine crushing. Chemical and Power Industry Chemical raw material processing: such as crushing…
The quality of roll crusher needs to be considered comprehensively from multiple dimensions such as structural design, material performance, manufacturing process, operation efficiency and after-sales service. The following are the specific evaluation points and technical basis: Quality Evaluation of Double-Roller Crushers Assessing the quality of double-roller crushers requires a comprehensive analysis of structural design, material performance, manufacturing processes, operational efficiency, and after-sales service. Below are key evaluation points with technical evidence: 1. Core Components & Material Performance A. Roller Skin Material & Wear Resistance The roller skin is the core wear part, directly impacting crushing efficiency and lifespan. High-quality crushers should use high manganese steel, alloy steel, or premium alloys, which provide hardness and wear resistance to handle high-hardness materials like steel slag (compressive strength ≤160 MPa). Inferior roller skins cause over-crushing or uneven particle sizes, compromising project quality. B. Bearings & Transmission System Gearboxes require regular gear oil lubrication, with seasonal adjustments (e.g., summer/winter oil changes). Rolling bearing temperatures must remain stable (monitored every 20 minutes until stabilized) to prevent overheating failures. 2. Structural Design & Manufacturing Precision A. Structural Stability Base components must be corrosion-free, deformation-free, and securely welded. Support brackets should be crack-free. Hydraulic systems must…
Selection of Smooth Rolls vs. Toothed Rolls for Double Roll Crushers The choice between smooth rolls and toothed rolls for double roll crushers requires a comprehensive evaluation of material properties, crushing requirements, and maintenance costs. Below are the detailed selection criteria and comparative analysis: I. Core Selection Criteria Material Hardness and Abrasiveness Smooth Rolls: Suitable for crushing high-hardness, highly abrasive materials (e.g., iron ore, quartz, cement clinker) via compression and grinding. They offer low wear rates and long service life. Toothed Rolls: Ideal for medium-hard or soft materials (e.g., coal, clay, shale). The teeth enhance crushing efficiency through shearing and splitting, but they wear faster and require periodic replacement of tooth plates. Output Particle Size Requirements Smooth Rolls: Produce finer output (1–10 mm), suitable for fine crushing applications like artificial sand production or coke crushing. Toothed Rolls: Generate coarser output (5–30 mm), ideal for medium crushing tasks such as raw coal primary crushing or middlings processing. Maintenance Costs and Durability Smooth Rolls: Feature smooth surfaces with uniform wear, resulting in lower maintenance costs and suitability for long-term, high-load operations. Toothed Rolls: Prone to tooth wear but can extend lifespan using high-manganese steel or alloy steel tooth plates. II. Other Key…
Steel slag is a by-product of iron and steel production generated in large quantities, effective treatment and full use of steel slag has become a key issue to promote the green transformation of the iron and steel industry and the development of circular economy. Roll crusher, as a kind of crushing equipment widely used in medium and fine crushing operations, its potential and effect in the application of steel slag crushing, is gradually receiving attention and attention from the industry. Steel slag is mainly composed of iron oxide, calcium oxide, magnesium oxide, silicate and other components, high hardness and different sizes. Steel slag is crushed to remove harmful substances and used in road construction, cement production, soil improvement and other fields. Therefore, the steel slag crusher needs to have high crushing efficiency, stable discharge size, wear resistance and other characteristics. Advantage analysis of steel slag roller crusher: 1. Precise particle size control By adjusting the gap between the two relatively rotating rollers, the roller crusher can accurately control the particle size of the crushed steel slag to ensure that the output material meets the particle size requirements of different applications. This feature is especially important for the resource utilisation of steel…
Below are the advantages and differences between roll crushers and hammer crushers based on the search results provided: 1. Structure and Working Principles Roller Crusher Structure: Consists of two counter-rotating rollers, an adjustment device (wedge or shim), and overload protection springs. Compact and simple design. Principle: Relies on high compression and shearing forces between rollers to crush materials. Offers precise control over output particle size (e.g., via shim adjustment). Advantages: Stable operation, minimal over-crushing, uniform particle size, and easy maintenance (replaceable roller surfaces). Hammer Crusher Structure: Comprises a rotor, hammers, and grate bars. Crushing occurs via high-speed hammer impacts. Principle: Uses kinetic energy from rotating hammers to break materials. Suitable for coarse and medium crushing (crushing ratio up to 40). Advantages: High throughput (up to 3,000 tons/hour), efficient for large-sized feed materials (up to 1,800 mm). 2. Applicable Materials and Scenarios Roller Crusher Materials: Best for brittle materials with medium hardness (e.g., coal, limestone, granite) and low moisture content (≤6%). Scenarios: Ideal for fine crushing (e.g., producing sand from materials like guamishi), where uniform particle size and minimal fines are critical. Limitations: Not suitable for high-hardness or irregularly shaped materials. Hammer Crusher Materials: Suitable for brittle materials with medium hardness…
rinciple of crushing materials by roll crusher? Roll crusher has a simple structure and is used for fine crushing operation of various high and medium hardness ores and rocks in mineral processing, chemical industry, cement, refractories, abrasives, building materials and other industries. Especially in the building materials industry to produce products such as guamite and sand making, there are more excellent results than general crushing machinery. Working principle: The main parts of the roller crusher: rollers, roller support bearings, compression adjusting device and driving device are divided into components. The two rollers are equipped with wedge adjusting device, the top of the wedge device is equipped with adjusting bolt. When the adjusting bolt pulls the wedge upward, the wedge will make the rollers away from the fixed wheel. The gap between the two rollers becomes larger, and the granularity of the crushed material becomes larger. When the wedge is downward, the movable rollers under the compression of the spring the gap between the two wheels becomes smaller. And the granularity of the material becomes smaller. Gasket device is through the increase or decrease in the number or thickness of the gasket to adjust the size of the discharge particle size….
What to look for when replacing roller skins ?Roll crusher crushes stones and wears out the roll skins as it crushes the material. It is necessary to check the condition of the roll skin regularly during production. Severe wear of the roll skin will affect the crushing capacity and product size, so it is necessary to replace the roll skin. Here, Huashengming Heavy Industry will explain the correct operation steps for replacing the roll skin of roll crusher: 1. The first step is to disconnect the power supply. 2. After cutting off the power supply, hang the warning sign of ‘under maintenance’ in a conspicuous position. 3. Next you can start to work, first of all, the lubrication pump to decompression processing. Will supply the belt rope switch pull good, clean up the belt head pumice, demolition of lifting down the mouth of the shroud, cauldron, cover plate fixed cone dust cover and other four pieces. During the lifting process, strictly observe the lifting operating procedures. 4. The liner could not be removed and gas welded and cut to clean the inside surface of the frame. The back of the liner was freshly poured concrete in a 1:3 mix of 500-600…
Roller sand making machine sand making effect, core advantages: particle size control, finished product quality, production efficiency and adaptability. Roller sand making machine has become the preferred equipment for the production of mechanism sand by virtue of its precise particle size control, high efficiency and energy saving, and strong adaptability and other advantages. In actual application, it is necessary to adjust the parameters with the material characteristics and pay attention to maintenance to maximise its performance. Roller sand making machine sand making effect Roller sand making machine Uniformity and adjustability of particle size Precise adjustment mechanism Adjust the gap between the two rollers of the roller sand making machine (wedge device or increase or decrease shims) to control the particle size of the material, the range is usually between 1-20mm, to meet the different requirements of the material. For example, when processing river pebbles, the finished sand grains have high roundness and low needle flake content, which is in line with the construction standard. Regular grain shape sand making effect The shape of the finished sand particles is mostly cubic or almost spherical. With internal cracks formed due to high-pressure extrusion. Low energy consumption for subsequent grinding and conducive to…
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