toothed roll crusher_henan yuhong heavy machinery co.,ltd
Raw materials: coal, coke, shale and limestone etcApplication: coal, metallurgy, mineral, chemical and construction industryCapacity: 30-300 t/hMax feeding size: 1050mmShipping ports: Shanghai, Qingdao or TianjinDelivery: 15-30 days
The Toothed Roll Crusher is suitable to the industries of coal, metallurgy, mineral, chemical and construction materials, and it is more suitable to crush raw coal (included gangue) of big coal mine or coal separating plant. The electrical motor and speed reducer was connected by distance limited hydraulic turbo coupling, which prevents the dynamic overload and sensor overload for safe operation. The distance between the toothed rolls is adjusted by hydraulic and the bearing or the toothed rolls was centralized lubricated. It has the features of optimal designing of gear shape, the choice crushing between tension and cutting, high efficiency with low consumption, uniform production size.
Toothed roll crusher consists of roll wheel, roll bearing, pressing device, adjusting device and driving device etc. Discharging size adjustment: between two roller equipped with cognate or gasket adjusting device, top of the wedge device capped with adjustment bolts. When the adjustment bolts pull upward wedge which will bear against the fixed wheel to make it deviate from the movable roller wheel, then the gap between wheels become large, discharging size become bigger, otherwise the opposite, gasket device is through the quantity or thickness to adjust the materials size. When adding gaskets the gap between wheels become large, when reducing gaskets the gap between wheels become small, so the discharging size becomes small. Driving structure is two motors through triangle belt drive to grooved pulley which drag roller rotating according to relative direction. In crushing stage, material is broken by roll wheel; final product is discharged from chassis. For safety, transmission part should be installed safety guard according to actual situation.
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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.
triple roll crushers | mclanahan
McLanahan Triple Roll Crushers are ideal for producers who want to accomplish two stages of reduction in a single pass. Depending on the duty class, they can be used in most ROM applications, such as coal, salt, lime, pet coke and potash operations. Triple Roll Crushers combine a Single Roll Crusher with a Double Roll Crusher to form a crusher that is capable of achieving a 6:1 reduction ratio in the primary stage and a 4:1 reduction in the secondary stage while producing a cubicle product at high capacities. An intermeshing tooth design means that no timing gears are required.
Offering the only Triple Roll Crusher in the minerals processing industry, McLanahan provides a crusher with a lower overall headroom requirement and a simplified process flow. The McLanahan Triple Roll Crusher also features hydraulic product size adjustment for both the primary and secondary crushing stages. This gives producers the option of changing size specifications or adjusting for wear if the need arises.
Triple Roll Crushers feature an automatic spring-and-toggle relief mechanism on both stages. This allows the crushing plate in the primary stage and movable roll in the secondary stage to open, safely pass uncrushable material and return to its original setting for continued operation. In addition to tramp relief, Triple Roll Crushers include access doors to assist with inspecting for wear or to facilitate roll maintenance. They are well guarded for personal protection.
The top stage of the crusher is made up of a toothed roll assembly, which crushes the incoming feed material against a crushing plate. This stage is designed to reduce larger feed sizes before feeding the secondary stage. 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 provide the producer with twice the wear life and simplified maintenance.
The secondary stage of crushing consists of a Double Roll Crusher arrangement. The secondary or bottom stage is fed directly from the top stage, where the feed material is channeled between the crushing rolls. A combination of compression and shear forces created between the 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 crushing plate, movable roll assemblies break open to allow the uncrushable item to pass. The tramp relief system then closes, returning both the crushing plate and movable roll assemblies to the previous setting while allowing the crusher to continue operating uninterrupted.
The ratio of reduction is the ratio of the feed size to the desired product size. For example, if the feed size is 12 and the desired product size is 3, then the ratio of reduction is 4:1. With Triple Roll Crushers, you have a 6:1 ratio on the top stage followed by a 4:1 ratio on the bottom stage.
Standard-Duty Triple Roll Crushers are the lightest-duty McLanahan Triple Roll Crusher and are designed to perform two-stage reduction of softer materials such as clean coal, salt, lime, trona and other materials.
Medium-Duty Triple Roll Crushers are designed to perform two-stage reduction of materials such as salt, potash, harder coals that contain medium-hard shale and slate, and other minerals, but are not suitable for hard rock and other similar materials. With both Standard-Duty and Medium-Duty Triple Roll Crushers, the drive consists of a cut tooth steel gear and pinion between the secondary stationary roll and the primary roll. In the secondary crushing section, the stationary roll drives the movable roll by means of an inter-stage V-belt drive.
Super Triple Roll Crushers are McLanahansheaviest-duty model of Triple Roll Crusher. Designed for high capacity ROM coal applications, they perform two-stage reduction and are capable of throughput of up to 7,000 TPH. Segmented roll shaft assemblies provide product sizing and long-lasting wear life. The Super Triple Roll Crusher is available in dual or three motor drives.
McLanahan Triple Roll Crushers allow producers to accomplish two stages of reduction in a single crusher. They feature a 6:1 reduction ratio in the primary stage, and a 4:1 reduction ratio in the secondary stage. This high capacity crusher simplifies the crushing process with a single machine and features an intermeshing tooth design, meaning that no timing gears are required. McLanahan offers the only Triple Roll Crusher in the industry.
double-toothed roller crushers for difficult materials
In recent year, mainly as a result of environmental problems, the raw material crushing sector has often had to use quarries in which the materials are imperfect or mixed with soil. This has made work difficult to traditional crushers, such as impact or jaw crushers, because they are often required to process materials for which they have not been designed.
Bedeschi machines have been installed in difficult location worldwide. The company promotes the spread and development of double-toothed roller crushers, which are employed in many different fields: cement plants, mining firms, brick and tile factories and company specialized in waste processing scrap material. They are basically very simply machines; they consist of two toothed rollers turning in opposite directions and the material to be crushed is made pass between them. The material is not crushed through compression but through a combination of shear and tensile stresses.
The processing system of the double-toothed roller crusher makes it possible to crush any type of raw material from hard (limestone and rock) to soft (clay, soil and mud) or even elastic-like wood or rubber tyres. The rotation speed, especially if compared to traditional crushers, is very low; so low, in fact, that tip speed is under 3 m/s.
These crushers have turned out to be particularly effective in situations where other crushers experience problems. They are ideal for processing wet, sticky materials, and blocks of hard material mixed with soil, in addition to crushing ordinary hard materials. Under these conditions, traditional crushers clog. Double-toothed roller crushers are equipped with scrapers, which keep the grooves and the work surface perfectly clean.
These crushers are invaluable for crushing clay, soil and sticky materials containing up to 30 % moisture content or rocks covered with a layer of soil, a situation that, as mentioned earlier, is often encountered due to environmental restrictions imposed on quarries. The majority of cement plants set up in the 1990s in the Far East where, because of the frequent rain, raw materials are very moist, are equipped with clay crushing systems with double roller crushers; most of them supplied by Bedeschi. These machines allow a maximum reduction ratio of ten at each crushing stage.
They can act as primary or secondary crushers and can be installed to suit any required arrangement, even one on top of the other, with the primary crusher discharging directly onto the secondary crusher.
The gap is adjusted in the factory according to project requirements but can be easily changed after the machine has been put into service, to improve or change crushing parameters. The roller gap of Bedeschi crushers can easily be adjusted to individual preferences.
The study and dimensioning of teeth is particularly important. Bedeschi technical staff, thanks to their calculation models defined over many years of experience, establish the characteristics and shapes that most suit the material to be crushed and the customers outlet size requirements. The most important and qualifying tooth characteristics are:
These crushers, due to their special crushing method, are characterized by their relatively low power consumption compared to traditional crushers. Many applications and tests confirm an average power absorption of 0.3 to 0.4 kWh/t.
Their special design, featuring an external reduction unit, allows compact sized machines to be made, which can be installed where space is at a premium; installations in tunnels are a particularly significant example.
Alfa Laval, irontrybex - stock.adobe.com; Nitta Corporation of Holland; ANDRITZ AG; Picture: Bedeschi; Profibus Nutzerorganisation; Ecoclean; Brkert; Namur ; malp - stock.adobe.com; Sinopec ; BASF; IFG Asota; Feige Filling; Emerson; Goodvibes Photo - stock.adobe.com; Steriline; Ima; Achema Pulse; Pixabay; WMFTG; Thordon Bearings; Leybold ; Oleksandr - stock.adobe.com; Evonik Industries; Siemens; Siemens Energy; Siemens Energy
single roll crushers | mclanahan
The Single Roll Crusher, with its 6:1 ratio of reduction, is ideal for reducing large feed lumps to a medium product size while producing a considerably lower percentage of fines. The minimum product sizing of a Single Roll Crusher is generally limited to 2-3. The crushing is carried out between the full width of the extra-long curved crushing plate and the low-speed crushing roll. The curvature of the crushing plate provides an ample throat opening to capture large irregular feed lumps. The replaceable crushing plate tips or liners are slotted to intermesh with the roll teeth to produce a cubical product and effectively reduce slabbing.
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.
These units are designed to make crushing simpler and more effective. McLanahan Single Roll Crushers also feature hydraulic product size adjustment to perform relatively simple changes to the crusher setting if required.
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 crushing plate to open and pass the tramp material. The crusher then returns to its previous setting and remains in operation.
Cobra Single Roll Crushers are the lightest duty in the McLanahan line of Single Roll Crushers. They are ideal for wet, sticky feeds and for processing materials such as clean coal, petroleum coke, sulfur, rosin, foundry cores, frozen agglomerates and other friable materials.
Rockmaster Single Roll Crushers are the heaviest-duty model in the McLanahan line of Single Roll Crushers. They are ideal for the most severe crushing applications and reduce extremely hard material and typical mine refuse.
Typically designed for primary crushing, McLanahan Single Roll Crushers efficiently crush material at a 6:1 crushing ratio. . They can continually withstand heavy-impact applications. Single Roll Crushers reduce large size particles in the feed to a medium size, while producing a low percentage of fines.