x double rolls crusher

double roll crushers gujarat, india

double roll crushers gujarat, india

Toothed Double Roll Crushers are used for crushing of friable and brittle materials like Coal, Coke, Sinter (hot and cold), Clay, Earth, Slag, Chalk, Soft Limestone etc. Due to cutting action of the teeth, crushing of material takes place mostly due to shear and not by pressing. Therefore fines generation is bare minimum.

Crushing takes place due to two rolls running in to each other and crushing the material caught in the valley of the rolls. One roll is fixed, while other one is adjustable & spring mounted, permitting un-crushable material to pass through.

Toothed rings are mounted on the heavy fabricated hub and the rings are kept, in position by holding bolts. These rings are made of wear-resistant steel, like Manganese Steel, or any other hardened steel depending upon the application.

Peripheral speed of rolls is kept between 3m-5m/sec and therefore up to 800 diameter roll crushers are driven, directly by V-belts. However, roll crushers above 800 mm diameter are provided with gear box/geared motor to keep the peripheral speed between specified limits of 3 m/ sec to 5 m/sec.

Gap Adjustment system is such, that during operation, gap can be adjusted along with the spring force. There are two spindles located one inside the other in such a way, that inner spindle tightens or losens the springs, while outer one changes the position of the roll.

We, at M/s. Rullitech Engineers are one of the leading manufacturers of Crushing like Stone Coal Crusher, Jaw Crusher, Reversible Impactor, Horizontal Shaft Impactor, Screening, Apron Feeder and Bulk Material Handling equipment.

automatic double roll crusher

automatic double roll crusher

Double roll crusher is mainly used for the crushing of medium or lower-hardness mines and rocks with medium or lower rigidity in mine selection, chemicals, cement and building materials industrial production. Roll crusher machine has a theoretical maximum reduction ratio of 4:1. If a 2 inch particle is fed to the roll crusher, the absolute smallest size one could expect from the crusher is 1/2 inch. Toothed roller crusher will only crush material down to a minimum particle size of about 10 Mesh (2 mm). Some major advantages of roll crushers are they give a very fine product size distribution and they produce very little dust or fines. Roll crushers are effectively used in minerals crushing where the ores are not too abrasive and they are also used in smaller scale production mining of more abrasive metal ores, such as gold. Coal is probably the largest user of roll crushers, currently, though. Coal plants will use roll crushers, either single roll or double roll, as primary crushers, reducing the ROM coal. Usually, these crushers will have teeth or raised forms on the face of the roll. (Roll crushers used for minerals and metal ores have smooth faced rolls.)

Tooth Roll Crusher is widely used for secondary and fine crushing in the industry of mining, building materials, chemical industry, metallurgy and so on. It can crush materials in middle hardness such as rocks, ore, coke, lump coal, slag, mineral slag, cement clinker, fireproof materials, etc.

Toothed Roll Crusher is worked by making two toothed roll rotate oppositely under the action of two pulleys on two sides of crusher, which driven by one motor or some motors. Thus the materials reaching the required size fall and discharged automatically, while the ones larger than two toothed rollers still left to be crushed until they reach the required size.A roll crusher using compression to crush, with two rolls rotating about a shaft, towards the gap between the rolls. The gap between the rolls is set to the size of product desired, with the realization that the largest feed particle can only be 4 times of the gap dimension. The particles are drawn into the gap between the rolls by their rotating motion and a friction angle formed between the rolls and the particle, called the nip angle. The two rolls force the particle between their rotating surface into the ever smaller gap area, and it fractures from the compressive forces presented by the rotating rolls.

1. Inside equipped with a dust excluding plate, good sealing, avoid the splash of fine material, less dust, low operating noise.2. Grinding roller is optimized, no need to replace the mill roll body during the whole life of equipment operation.3. Adopts wear-resisting plates (also named roller skin); use foreign advanced wearable technology for wear liners; if wear liner is badly worn, you can weld it by electrode wear and polish it.4. Big crushing ratio, after crushing powder content is below 5%; especially suitable for crushing of quartz sand industry.5. Indispensable auxiliary equipment for regulating the fineness of products in sand making industry.6. Average discharging size without blocking up.7. Automatically screening the materials after crushing.8. High efficiency and low energy consumption.9. Good flexibility and operational reliability.10. Removable shell which is convenient for daily maintenance and inspection of the machine.

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double roll & teethed roll crusher

double roll & teethed roll crusher

Although its brief period of popularity passed some thirty-odd years since, and only a few sets were installed before interest reverted to other types, the high-speed double roll crusher developed by Thomas A. Edison shortly before the end of the last century warrants a place in any discussion-of crushing equipment. In 1960, the largest machine of this type the 6 x 7 foot giant rolls were huge crushers, judged even by present-day standards; they have an unobstructed receiving opening 7 x 7 foot and their capacity on individual skip-loads of stone is enormous, although, as will be explained, they cannot maintain this peak capacity over a period of time.

Mechanically, the teethed roll crusher is a very simple machine. The two rolls are carried in bearings, supported on two very heavy and rigid bed castings which are secured on the concrete foundation by a number of large anchor bolts. The bearings, in addition to being bolted to these bed castings, are prevented from spreading by pairs of large tie-rods which pass through them above and below the roll shafts. Unlike the smooth-face crushing rolls we have described, these tension rods are not cushioned by springs. The machine is surmounted by a heavy cast rectangular hopper, all sides of which are vertical. Each roll is independently driven by a flat-belt pulley.

The roll-centres are octagonal in cross section, each face being provided with a spline groove and a series of tapped holes for securing the chilled- iron wearing plates. These wearing plates have the sledging knobs, or teeth, cast on their outer surfaces. Thus we have a roll surface that resembles that of the one rollcrusher, except that the faces of all teeth are sloped instead of radial on the advance side. The usual practice is to fit one roll entirely with so-called regular teeth, and the other roll with six rows of regulars and two rows of higher (slugger) teeth.

The peripheral speed, or tip-velocity, of these rolls is much higher than that of any of the machines we have previously described. The range of the smooth-face rolls, for example, is from about 400 ft/min for the small 12-in. rolls, to 2000-2200 feet/minute for the heavy-duty 72 machine. The single-roll crusher has a tip speed of 400-450 ft/min while the 6- x 7-ft teethed roll crusherhas a normal, no-load, surfaces speed of just under 3500 ft/min. It can be readily appreciated that this high velocity induces an extremely violent crushing action, in conjunction with the 3- to 4-in. knobs which protrude from the roll surfaces. Impact, sledging, and pressure crushing enter into the over-all performance; but impact, in this crusher, plays a far more important role than it does in the slower speed single-roll machine; and crushing, even well down along the roll faces, is more in the nature of a sledging action than it is of pressure crushing, for this action occurs in the lower-velocity crushers.

The theoretical maximum size of cube that the knobs will grip, when the rolls are set at minimum spacing, is 24; but the rolls will reduce any stone that can be introduced into the 7-ft square hopper. Large blocks will span across the tops of the two rolls; immediately the slugger teeth on the one roll so equipped go to work on these blocks and quickly shatter them into pieces that can be gripped between the sets of regular teeth; from this point on, the action is a mixture of sledging and pressure crushing. The same selective segregations which we described in connection with the single-roll machine occur in the double-roll crusher; the smaller pieces are cleared quickly, leaving the roils free to work on the larger blocks.

The entire performance on individual skip-loads of stone takes place in a very short period of time. Ten- ton loads of mixed-size medium limestone will clear the crusher in from 10 to 15 sec.; large single blocks, weighing from 6 to 8 tons, are crushed in from 5 to 20 seconds, depending upon the toughness of the individual piece, and upon the way it happens to land in the crushing chamber. These performances were clocked on ma-chines turning out a 6 product.

The short-time transfer of energy, especially when crushing large blocks, is very high; so high in fact that it would not be economically feasible to provide sufficient motive power to deliver it. The usual practice, when these rolls are driven electrically, is to drive the slugger roll with a 250 HP motor, and the regular roll with 200HP,a total of 450 HP. As compared to this motive power, instantaneous energy delivery may run as high as 4000 HP, obviously far beyond the capacity of the motive equipment. But the rolls themselves, when running at normal no-load speed, have a stored kinetic energy of upwards of 4,000,000 ft -lb , and it is this stored energy that does much of the actual crushing, the motors serving to bring the rolls back to normal speed between crushing periods. In crushing a skip-load of stone the rolls may lose anywhere from 30 to 60 RPMin speed; this loss occurs partly through slowing down of the motive equipment, and partly through belt slippage. It requires from 5 to 10 sec. to bring the machine back to speed, during which time the power input will vary from 400 to 600 HP. The power required to run the rolls empty is something less than 100 hp. The average power consumption, when crushing from 3000 to 4000 tons per 10 hour day will run in the neighbourhood of 150 HP on medium limestone.

While the average power consumption of this machine compares favorably with that of other types, the rather violent fluctuation outlined and the relatively high connected horsepower are unfavourable features. It is also natural to expect that the belt slippage we have noted would constitute something of a problem over a period of time. Performance records indicate that belt trouble accounts for about 50% of the total lost time on a set of these rolls, and about 25% of the total maintenance expense.

The type of quarry equipment most commonly used in conjunction with this crusher is the three-sided steel skip, carried on a flat-top truck or flat car. These skips are provided with a shackle on the rear end, which is engaged by a hook actuated by a small hoist. This apparatus slides the skip over against the lip of the receiving hopper, and tilts it to discharge its contents. The skips discharge over a feed-roll which retards the flow of material so that the entire load does not drop into the crushing chamber at once. When the skip is empty it is pulled back on to the truck or car by a counterweight attached to the opposite end of the same cable which performs the hoisting operation.

We have mentioned the heavily ribbed hopper which surmounts the frame and extends up to the level of the feed roll. This hopper serves the double purpose of directing the material into the crushing zone, and preventing stones thrown by the slugger teeth from flying out of the crusher. It is also necessary to cover the top of the hopper with heavy netting to contain flying spalls.The straight-sided, rectangular hopper construction, and the violent agitation in the crushing chamber, tend to minimize blocking and bridging in this crusher. When bridges do occur they are difficult and dangerous to break while the rolls are running.

Practically all that we have had to say about the application of the single-roll crusher will apply as well to the Edison toothed roll crusher. It is better adapted to handling blocky stone than is the single-roll machine, because itsslugging action is much more vigorous, and it will handle any material that will not build up on the sides of the vertical hopper. It is not as simple a machine to feed as the single roll crusher, because its narrow hopper necessitates the uses of skips, or very short-bodied cars. A heavy- duty apron feeder would of course solve this problem, but so far as we know, none of these crushers were so equipped. The high peak capacity of the crusher constitutes something of a problem in plants of medium capacity. It is not economically feasible to provide elevating or conveying equipment to handle peak loads of around 4000 TPH in a plant designed to turn out that much stone in an 8 or 10 hr day; consequently means must be provided to smooth out these high surge loads. This can be taken care of by a surge bin and feeder below the crusher, or by passing the roll product direct to a secondary crusher of uniform-capacity characteristic. A feeder ahead of the rolls would smooth out peaks on mixed feed but. once a 10 or 12 ton block of stone is dropped into the crusher, that quantity comes through very quickly as crushed stone, which would render the regulating properties of the feeder of questionable value.Modified forms of this crusher were used by Edison for secondary and tertiary stages. The crushing equipment in one large plant, for example, comprised a set of 6- x 7-ft rolls (8 product), a set of 4 x 4 feet secondary rolls (3.5 product), and a set of 4 x 3 ft tertiary rolls (1.5 product), these last rolls being in closed circuit. These smaller machines were also run at high speeds, their surface velocities being slightly over 3000 ft/min.

double roller crusher - jxsc machine

double roller crusher - jxsc machine

Capacity2-140 T/H Fedding size150mm Discharge size2-50m Crushing MaterialRiver pebble, granite, basalt, iron ore, limestone, quartz, gangue and so on. ApplicationSuitable for crushing brittle bulk materials in cement, chemical, electric power, mining, metallurgy, building materials, refractory materials, coal mines, etc.

Whats the double roller crusher The Doule Roller Crusher, also known as roll crusher, toothed roll crusher, is suitable for fine crush the medium hardness rock with compressive strength 160MPa, such as ore, rock, coke, coal, clinker, ceramic raw materials, slag, refractory materials, and chemical materials. According to the number of rolls, the roll crushers can be divided into single roll crusher, double roll crusher or, four roll crusher. Double roll crusher is the most used type. We produce industrial roller crushers and laboratory uses small roll crusher. Advantages Replacement wear-resistant lining, long service life, convenient maintenance. Compact structure, lightweight, small size, for the same production capacity requirements of the crushing system, equipped with roller crusher can significantly save investment. The width of the discharge opening can be adjusted to determine the crushed material size. High reduction ratio, low vibration, dust removal, and less noise. High efficiency, low consumption, uniform granule, good granule shape. Roller crusher manufacturer JXSC, a Chinese rock crusher manufacturer, supply roll crushers global, we establish a wear parts supply system to meet customers parts replacement needs are met and reduce the downtime. Factory price, fast delivery, one year warranty, on-site installation, support roll crusher design.

Main partsBearing box, roll shell, bearing housing, adjusting rod, motor, carrier, fixed roller, movable roller and safety spring, etc. Working Principle of Double Roller CrusherThe roller of the roller crusher is supported by the spring pressure. Under normal working conditions, the spring force is sufficient to overcome the crushing force of the crushed material. By changing the number of spacers between the frame and the movable bearing, the width of the discharge port between the two rolls can be adjusted to adjust the grain size. When there is a material that cannot be broken into the crushing chamber, the spring is compressed, and the movable roller is retracted to increase the discharge opening. After the material is discharged, the movable roller is reset under the spring pressure. OperationThe main wearing part of the roller crusher is the crushing roller. Precautions as follows: Iron removal before crushing; prevent sticky mud clogging; pre-pick out the large ore rock; good lubrication condition.

double roll crushers | mclanahan

double roll crushers | mclanahan

Double Roll Crushers typically follow a primary or secondary crusher and are used for secondary and tertiary reduction of various minerals, such as ROM coal, clean coal, limestone, gypsum, trona, shale, bauxite, oil shale, coke, salt, lime, glass, kaolin, brick, shale and wet, sticky feeds. They are one of the most widely used crushers in the mining industry and have numerous advantages, such as high capacity, low headroom, low horsepower, the ability to handle wet, sticky feeds and the ability to produce a cubical product with minimum fines generation. Roll diameters and widths are dictated by the feed size, product size and capacity. The rule of thumb for the Double Roll Crushers ratio of reduction is 4:1.

The simplified design gives these units excellent reliability and requires very little maintenance. The crushers are designed with built-in tramp relief that allows for the passing of uncrushable objects while remaining in continuous operation and returning to the initial product setting. With a variety of roll surface designs, this crusher is capable of producing a much finer product. Since each machine is custom engineered, roll elements and tooth patterns are selected depending on each unique application.

McLanahan Double Roll Crushers feature slower roll speeds and a larger surface area to add prolonged life to the crushing elements, resulting in less maintenance downtime and decreasing your cost per ton. Double Roll Crushers generate minimum fines while producing a cubical product.

McLanahan Double Roll Crushers are designed for safety and many years of rugged operation. Effective tramp protection against non-crushable material is provided by an automatic spring-and-toggle system. This allows a movable roll to open, pass the material and return to its original setting for continued operation. Hydraulic product size adjustment allows producers to adjust for changes in product size requirements or to compensate for roll wear.

Operating Double Roll Crushers is quite simple. Whether it is a single or dual drive arrangement, the rolls are powered by electric motors and V-belt drive configurations, resulting in reliable and quiet operation. If it is a single drive arrangement, power is transferred from the driven roll to the non-driven opposing roll by an interstage V-belt drive. If it is a dual drive configuration, each roll is powered independently through a motor and V-belt drive.

During normal operation, the material is fed between the crushing rolls. A combination of compression and shear forces created between the opposing rolls reduce the feed material to the desired product size while producing a cubicle product with minimum fines.

McLanahans mechanical tramp relief systems employ a spring-and-toggle mechanism that activates whenever an uncrushable object enters the crushing chamber. Once an excessive force is applied to the movable roll, the toggles break open to allow the uncrushable item to pass. The high torsion springs then close the toggles, returning the movable roll to the previous setting. The crusher continues to operate uninterrupted.

When an uncrushable object, such as metal, roof bolts/timbers, etc., enters the crusher and the force necessary to crush this material is greater than the crushing forces of the crusher, the crusher allows the moveable roll to open and pass the tramp material and then return to its previous setting and remain in operation.

Depending on the customers desired product size and fines consideration, Mineral Sizers or Hammermills could be considered. The reasons people would consider a Roll Crusher over these alternative technologies include lower power requirements, less fines generation and costs.

Black Diamond Double Roll Crushers are the most versatile and popular model of McLanahan Double Roll Crushers. Ideal for secondary and tertiary crushing applications where product requirements drop down to (6mm), Black Diamond Double Roll Crushers are most commonly used to crush clean coal or friable materials with little or no hard refuse. They are available with single or dual V-belt drive.

Heavy-Duty Double Roll Crushers are ideal for the primary, secondary and tertiary crushing of limestone, gypsum, ROM coal, etc. where higher compressive strength material is anticipated. Due to the V-belt drive design, a lower horsepower is required compared to other crushers designed for the same applications.

Shalemaster Double Roll Crushers are driven mechanically with V-belt drives and gear reducers. They offer the same durability as other McLanahan Double Roll Crushers but are designed to handle wet, sticky feeds such as soft shale, kaolin and clay. The Shalemasters special tooth design and differential roll speeds provide optimum performance against plugging and other problems often associated with handling sticky materials.

Typically used as secondary or tertiary crushers, McLanahan Double Roll Crushers provide a 4:1 reduction ratio and can be used following other McLanahan equipment, such as Feeder-Breakers, Rotary Breakers, primary DDC-Sizers, or Single Roll Crushers, when further reduction of primary crushed material is required. Each Double Roll Crusher is selected and engineered for its specific application, thus roll elements and tooth patterns are selected based on the customers unique applications and designed to produce a cubical product with minimal fines.

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