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Roll crusher (roller crusher) is suitable for the fine crushing of the materials with feeding size less than 110mm, and finished particle size 3-30mm.
Roller diameter: 400-700mm
Applied materials: Limestone, slag, coke, coal, salt, chalk, gypsum, alums, brick, tile, etc.
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Single Roll Crushers are V-belt driven and employ a large diameter flywheel with a gear and pinion set to reduce roll speed. With the assistance of the inertia generated by the flywheel, this crusher is operated with relatively low horsepower and requires lower headroom in comparison to other crushers used for primary reduction. The roll diameter and width of the crusher will ultimately be dictated by the feed size, product size and capacity.
Single Roll Crushers employ a tramp relief mechanism to allow momentary movement of the crushing plate so the uncrushable object can pass. The mechanism then allows the crusher to return to its original setting and remain in operation.
The Single Roll Crusher, which was originally patented by Samuel Calvin McLanahan in 1894, has evolved over the years to include design features to ensure many years of rugged operation. Complete with all safety guards, the Single Roll Crusher features an automatic tramp relief mechanism that allows the crushing plate to hinge open, pass non-crushable tramp material and return to the previous setting for continued operation.
Based on the application data and extensive field experience, McLanahan selects the proper duty class of Single Roll Crusher for each project. A fully-equipped application research laboratory allows for crushing tests to make sure McLanahan can provide the best possible solution.
A Single Roll Crusher is made up of a toothed roll assembly, which crushes the incoming feed material against a crushing plate. The Single Roll Crusher is designed to reduce larger feed sizes to the desired product size at a 6:1 ratio of reduction while producing a considerably lower percentage of fines. When properly fed in the direction of the roll rotation, the crushing action is carried out along the full width of the curved crushing plate, which ensures maximum throughput capacity. A properly sized roll diameter and tooth configuration grabs the incoming feed and pulls it into the crushing zone without hesitation. The crushing plate has reversible and easily replaceable crushing plate tips, which are designed to produce a cubical product while providing the producer with twice the wear life and simplified maintenance. Single Roll Crushers often require less horsepower and lower headroom in comparison to other crushers used in primary and secondary applications.
Double Roll Crushers are designed for single-pass size reduction of medium-hard to hard materials such as rock or ore to a nominal minus 10 mesh. Topsize is approximately 13mm and final fineness typically passes a No. 10 (2mm) opening, depending on material type. Roll Crushers work well in preparing samples for further fine reduction using a pulverizer. Output size is controlled by adjusting the gap between the rollers using a hand lever. Feed hoppers offer high capacity, open easily for cleaning and maintenance access, and feature an electrical safety interlock that shuts down power to the unit when the hopper is opened
The crushers are rugged with easy-to-operate capabilities that meet the rigorous demands of laboratory and pilot plant operations. The Double Roll Crushers are mounted on a heavy steel base, include strong relief springs, and are fully-equipped with safety guards. These crushers are constructed of fabricated steel and equipped with a fabricated steel drive guide for operator safety. They have a tilt-design feed hopper, cast Ni-hard roll facings for long-life, relief springs, and heavy-duty pillow block bearings
LC-13 Marcy® Double Roll Crusher features 6.5x6in (165x153mm), Dia.xW heavy 304 stainless steel crushing rolls with Ni-hard roll facings. The 2hp TEFC motor with V-belt drive produces a uniform speed throughout the crushing process. This model is capable of reducing most rock-like materials of 0.5in (13mm) feed size to minus No. 10 (2mm) at a capacity up to 3,000lbs (1,361kg) per hour. Operates at 60Hz. Voltage of 230V or 460V must be selected at time of order
LC-14 Marcy® Double Roll Crusher features 9x12in (229x305mm), Dia.xW heavy 304 stainless steel crushing rolls with Ni-hard roll facings. The unit features a V-belt drive, with a 5hp TEFC motor that produces uniform speed throughout the crushing process. It can reduce most rock-like materials of 0.5in (13mm) feed size to minus No. 10 (2mm) at a capacity up to 8,000lbs (3,629kg) per hour. Operates at 60Hz. Select preferred voltage of 230V or 460V when ordering
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A roll crusher is a piece of heavy-duty equipment used in mining and industrial processes. It features a pair of large wheels or cylinders mounted on horizontal axis. When rocks, ore, and other materials pass between the two cylinders, they are crushed or ground into smaller pieces. A roll crusher can be used in a wide variety of applications, including concrete recycling, coal mining, and mineral or metal production
In a standard double roll crusher, the two cylinders each feature a steel or ceramic finish. A hopper or bin above the rollers drops rocks and other materials down into the gap between cylinders. The two cylinders rotate in opposite directions to force all materials into the space between the two units as it falls. The friction between the two wheels crushes the material, which then falls into a collection bin below the unit. Users must set the space between the rollers to match the desired size of the crushed particles
The surface of the roll crusher may be smooth or textured, depending on the applications. Roll crushers used to crush rocks and other heavy-duty materials generally feature teeth or spikes along the surface of each cylinder. Smooth-faced cylinders are used to crush more delicate materials, including minerals and some metals.
If the double roll crusher does not produce a fine enough material, a four-way roll crusher may be needed. In this type of machine, the pulverized material passes through the first two cylinders into a second set of cylinders located below the first. The second set of rollers crushes the material once more to achieve a finer finished product.
Roll crushers have 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. Roll crushers will only crush material down to a minimum particle size of about 10 Mesh (2 mm). A roll crusher crushes using compression, 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 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. Some major advantages of roll crushers are they give a very fine product size distribution and they produce very little dust or fines. Rolls 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.)
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