Introduction: With its compact structure, precise particle size and low over-crushing rate, roll crusher undertakes key crushing tasks in a number of industrial fields. The following is a det...

With its compact structure, precise particle size and low over-crushing rate, roll crusher undertakes key crushing tasks in a number of industrial fields. The following is a detailed description of its core application scenarios and industry cases:

1. Coal Industry

1. Raw Coal Coarse/Medium Crushing

• Scenario: Raw coal (≤300mm) is crushed to 30-50mm for washing and processing.
• Advantage: no need to remove gangue (direct processing of gangue-containing coal), simplify the process, hourly output of up to 100-200 tons.
• Case: A coal processing plant adopts 2PG1200×1000 toothed roll crusher, coke particle size after processing ≤ 3mm, over crushing rate <5%.

2.Coke fine crushing

• Scenario: Coke (≤80mm) is crushed to ≤3mm for blast furnace blowing fuel.
• Equipment selection: double-toothed roll crusher with surfaced tungsten carbide roll face, with wear-resistant life up to 8 months.

2、Building materials industry

1. Limestone aggregate processing

• Scenario: Limestone (100-150mm) after jaw crushing is crushed twice to 5-10mm for cement raw mill.
• Characteristics: Smooth rollers reduce dust (emission <10mg/m³), closed design meets environmental requirements.

2. Clay/gypsum crushing

• Scenario: sticky materials (such as clay) are crushed to ≤2mm, and a scraper clearing device is required to prevent sticking rollers.
• Case: A cement plant uses 2PG800×600 hydraulic rollers, and the uniformity of the processed material is improved by 20%.

3、Metallurgical industry

1.Pellet ore pretreatment

• Scenario: the mixture of iron ore concentrate and binder is crushed to ≤3mm to ensure the quality of pellet sintering.
• Equipment features: double roll design with scraper to prevent material bonding, hourly output of 80-150 tons.

2.Steel slag fine crushing

• Scenario: steel slag (≤50mm) is crushed to ≤5mm, used as road base material or recycled metal.
• Advantage: high chrome alloy roll surface is wear-resistant, annual maintenance cost reduced by 30%.

4、Chemical & Power Industry

1. Phosphorus Ore Classification Crushing

• Scenario: Raw ore (≤300mm) is crushed by one section of coarse crushing (25mm) and two sections of fine crushing (≤3mm) for acid digestion or ammonium phosphate production.
• Equipment configuration: double-section toothed roll crusher with total power of 320kW and hourly output of 150 tons.

2. Coal gangue raw material processing for power generation

• Scenario: coal gangue (≤100mm) is crushed to ≤5mm for circulating fluidized bed boiler fuel.
• Case: A power plant adopts mobile roller crushing plant with a processing capacity of 80 tons/hour, reducing transportation costs by 60%.

5、Environmental Protection and Renewable Resources

1.Construction Waste Recycled Aggregate

• Scenario: Concrete blocks are crushed to 0-5mm recycled sand and 5-20mm aggregate, replacing natural stone.
• Technical points: integrated jaw crusher + roller crusher + screening, integrated design to adapt to decentralized processing.

2. Industrial waste slag recycling

• Scenario: slag, fly ash, etc. are finely crushed to ≤3mm and used as concrete admixture.

Advantage: low noise (<80dB) and closed structure to reduce secondary pollution.

6、Special Scenario Application

1. Ultra-fine crushing of glass raw materials

• Scenario: quartz sand crushing to 0.1-0.5mm, reducing energy consumption of the furnace.

Equipment selection: ceramic coated roll surface, particle size centralized distribution (0.1-0.3mm accounted for 75%).

2. Ceramic raw material preparation

• Scenario: kaolin and feldspar crushing to ≤2mm, improve sintering efficiency.
• Case: A ceramic factory uses glossy roll crusher to increase the yield rate by 15%.

Key Scenario Adaptability Summary

sector	Applicable materials	Particle size range	ceore valu
coals	Raw coal, coke	30-50mm→3mm	Simplify the coal preparation process and reduce the over-crushing rate
building materials	Limestone, clay	100mm→5mm	Enclosed low dust, uniform particle size
metallurgical	Iron ore concentrate, steel slag	50mm→3mm	Anti-bonding design for improved pellet quality
metallurgy	Phosphate ore, gangue	300mm→3mm	Multi-stage crushing saves space and energy
eco-friendly	Construction waste, industrial waste	100mm→0.5mm	Recycled Aggregate Production to Reduce Resource Waste

Selection Notes

1. Material Characteristics:

• Hardness ≤160MPa (such as coal, limestone);
• viscous materials need to choose models with scraper or toothed rollers.

2. Capacity requirements:

• 2PG400×250 for less than 50 tons per hour;
• 2PG1500×1000 for more than 200 tons per hour.

3. Intelligent configurations:

• Hydraulic gap adjustment, automatic compensation for roll gap wear, overload protection (spring/hydraulic system).

By accurately matching the industry demand and equipment parameters, the roll crusher can significantly improve the crushing efficiency and reduce operating costs, and is the first choice of equipment for the fine processing of medium and low hardness materials.