Double Roll Crusher
Double Roll Crusher: Your Guide to Efficient and Reliable Size Reduction
Table of Contents
What is a Double Roll Crusher?
A Double Roll Crusher is a robust and versatile compression-type crusher primarily used for the secondary and tertiary crushing of medium-hard to soft materials. As the name suggests, it features two counter-rotating rollers that draw material into the crushing chamber. The material is then compressed and sheared between the roller surfaces, breaking it down into a controlled product size with a minimal fines fraction.
Known for its simplicity and reliability, the Double Roll Crusher is a preferred choice in industries like mining, coal, cement, and chemical processing where a consistent product with minimal oversize is critical.
Double Roll Crusher Working Principle
The operating principle of a Double Roll Crusher is straightforward yet highly effective, relying on compression and friction. Here’s a step-by-step breakdown:
Feed Introduction: Raw material is fed evenly into the top of the crusher from a hopper.
Capture and Draw: The two massive rollers, rotating towards each other, capture the feed material. The surface of the rollers (which can be smooth, corrugated, or toothed) grips the particles and pulls them into the narrowing gap between the rollers.
Compression and Crushing: As the material moves into the gap, it is subjected to immense compressive force. The particles are crushed by being compressed against each other and against the roller surfaces. This action creates a “nipping” effect, similar to a nutcracker.
Product Discharge: The crushed material passes through the gap between the rollers and is discharged out the bottom. The final product size is determined by the gap setting between the two rolls, which can be mechanically adjusted to achieve the desired output.
This direct compression mechanism makes it exceptionally efficient for specific applications, reducing the generation of dust and fines compared to impact crushers.
What Materials is a Double Roll Crusher Suitable For?
The Double Roll Crusher is highly versatile but excels with specific types of materials. It is ideally suited for crushing:
Coal: Its primary application, perfectly crushing run-of-mine coal to a uniform size for washing plants or direct sale.
Soft to Medium-Hard Minerals: Such as limestone, gypsum, chalk, and clay.
Oil Shale & Salt: Materials that are friable and can be easily compressed.
Coke: Used in the steel and foundry industries.
Frozen Aggregates: Effective in breaking up frozen lumps of sand or aggregates.
Brittle Materials: Like sinter, glass, and certain fertilizers.
Note: It is generally not recommended for very hard, tough, or abrasive materials like granite or quartzite, as they cause excessive wear on the rollers.
Double Roll Crusher Models and Specifications
We provide a comprehensive range of Double Roll Crushers to match various capacity requirements and feed sizes. Below is a table of our popular models.
Table: Double Roll Crusher Models & Technical Parameters
| Model | Roll Diameter (mm) | Roll Length (mm) | Max Feed Size (mm) | Output Size (mm) | Capacity (t/h) | Power (kW x 2) |
|---|---|---|---|---|---|---|
| 2PG-0605 | 600 | 500 | < 70 | 0-10 | 10-40 | 7.5 x 2 |
| 2PG-0807 | 800 | 700 | < 80 | 0-15 | 20-60 | 15 x 2 |
| 2PG-1010 | 1000 | 1000 | < 90 | 0-20 | 40-100 | 30 x 2 |
| 2PG-1212 | 1200 | 1200 | < 100 | 0-25 | 70-150 | 45 x 2 |
| 2PG-1616 | 1600 | 1600 | < 150 | 0-40 | 150-350 | 90 x 2 |
Key Advantages of Double Roll Crushers
Why choose a Double Roll Crusher over other types of crushing equipment? The benefits are clear:
Compact Design & Low Height: Their streamlined profile makes them easy to install in confined spaces and requires less headroom than cone or jaw crushers.
Minimal Fines Generation: The compression action produces a product with a more uniform grain size and significantly less dust and ultra-fine material compared to impact crushers.
Simple & Adjustable Output: The gap between rolls can be easily adjusted, even during operation in some models, allowing for quick and precise control over the final product size.
Low Operating Costs: With a simple mechanical structure, maintenance is straightforward, and wear part replacement (like roller shells) is cost-effective.
Overload Protection: Many models feature a spring-release mechanism or hydraulic system that allows the rolls to separate if an unbreakable object (tramp iron) enters, protecting the machine from severe damage.
Versatile Roll Surfaces: Rollers can be fitted with smooth, corrugated, or tooth-style shells to best suit the material being processed, from fine crushing of coal to primary breaking of limestone.
Double Roll Crusher vs. Traditional Crushers
How does it stack up against other common crushers?
Vs. Jaw Crusher: Jaw crushers are great for primary crushing of very hard materials but produce a more slabby product. Double Roll Crushers offer a more controlled, cubicle product at a lower cost for secondary duties on softer materials.
Vs. Hammer Crusher: Hammer crushers generate a high percentage of fines and have higher wear costs due to the velocity of the hammers. Double Roll Crushers offer lower wear costs and a cleaner, more predictable product size distribution.
Vs. Cone Crusher: Cone crushers are high-capacity machines for hard, abrasive stone but are more complex and expensive to purchase and maintain. For softer materials, the Double Roll Crusher is a far more economical and efficient solution.
We Provide a Full Range of Double Roll Crusher Solutions
Selecting the right crushing equipment is key to your operation’s profitability and efficiency. As a leading supplier of size reduction equipment, we are dedicated to providing custom-tailored Double Roll Crusher solutions for a global clientele.
We offer a wide array of Double Roll Crusher models and configurations. Our technical team will collaborate with you to:
Analyze your material characteristics and production goals.
Recommend the optimal crusher model, roll surface, and drive configuration.
Provide end-to-end project support, from installation to commissioning.
Ensure long-term performance with readily available genuine wear parts and expert service.
Don’t compromise on your crushing process. Contact us today to find the most efficient and reliable Double Roll Crusher for your specific application and unlock new levels of productivity.