reliable toothed roll crusher | fote machinery
Applied material: coal, pebble, perlite, limestone, dolomite, etc. Its outstanding features: high crushing capacity, hadraulic pressure used to adjust the distance between the rollers, and the centralization lubrication on the brearing.
The toothed roller crusher is generally used for the medium and fine crushing for brittle and medium-hard ores, and the size of the crushed product is usually not less than 20mm. Because of its simple structure, easy maintenance, and low price, it is popular to aggregate and coal ores suppliers.
A double toothed crusher with less volume is composed of two toothed rollers which is installed in parallel and rotates in opposite directions. The two-toothed rollers adopt non-meshing and non-constant speed operation to strengthen the degree of occlusion, which ideally prevents the material from slipping thus improving the crushing efficiency.
Generally speaking, materials are crushed in three stages in a double toothed roller crusher. The material enters the crushing chamber by the impact force of the deep tooth gear for the first crushing. The large-block material is cut by the teeth to complete the second crushing, and then being squeezed when they enter the toothed rollers to complete for the third crushing. Finally, the crushed material is discharged from the outlet with the rotation of the toothed roller.
1. The company makes further improvement in the aspects of feed particle size, rotor diameter, rotor channel, etc., so that this series of products can adjust the corresponding rotor structure and the corresponding speed according to different materials and feed grain levels to cooperate, and can achieve higher production volume and higher fineness modulus.
In recent years, with the transformation and upgrading of the coal industry, the requirements for coal development efficiency and environmental protection are increasing day by day. In the field of coal chemical industry, the requirements for product particle size are extremely strict, and generally the particle size is between 25 mm and 70 mm.
If the particle size is too large, the crusher chamber will be blocked, and downstream processing cannot be carried out. The toothed roll crusher is currently used in coal crushing because of its large processing capacity, low fine powder producing rate.
The crusher teeth are composed of big and small tooth phase interval, which can effectively improve the meshing capacity gear roller with the ensure of ideal particle size. Strong meshing capacity can improve the equipment processing capacity, reduce the tooth roller wear, prolong the tooth plate service life.
The connection between tooth plate and tooth roller base is made by screw fastening block, which not only guarantees the connection strength, but also has good interchangeability and replaceability.
Carbon bainite wear - resistant cast steel is used as the material of the tooth plate. The wear resistance of this material is about 40% higher than that of 40Cr surface-welded wear resistant layer. In addition, the whole tooth roller structure, including tooth plate, tooth roller seat, thread fastening block makes strength and hardness of each component more balanced and reasonable.
Besides, the motor is equipped with an electric heating system, and the hydraulic coupler and reducer are made of low temperature synthetic oil which ensures the transmission system smooth operation in the low temperature even with minus 30 .
The Indian customers coal mine adopts the single-bucket truck with semi-continuous mining process, and the raw coal has large grain size, gangue with great hardness. In the original production line, he firstly crushed the material to less than 300mm, then crushed them to less than 70mm by a ring hammer crusher. The crushed material with 70mm was transported to the coal storage bunker by conveyor belt for screening to final products of 25 ~ 70mm.
Technical improvement is urgently needed in order to reduce the operation cost and labor intensity of workers, and ensure the normal operation of the production system. So, the user finally chose Fote toothed roll crusher to replace the original ring hammer crusher.
After the double toothed roller crusher is put into use, the equipment runs stably, and the output particle size of the product has been improved obviously. The comparison shows that there is a 18.2% difference between the qualified products before and after the equipment replacement, which greatly increases the output of the qualified products and creates great economic benefits for the enterprise.
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Based on the high quality and complete after-sales service, our products have been exported to more than 120 countries and regions. Fote Machinery has been the choice of more than 200,000 customers.
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.
toothed roll crusher for coal preparation plant - ftm machinery
Toothed roll crusher is widely used in coal, metallurgy, mining, chemical industry, building materials, and other industries, and it is more suitable to crush coal in large coal preparation plant and process waste. Toothed roll crusher has a high crushing capacity. The distance between the rollers can be adjusted by hydraulic pressure. The bearing of the toothed roll crusher is centralization lubrication. Whats more, it has the advantages of optimal design, high efficiency, uniform grain, and low cost.
Protective device: The motor is connected with the retarder through hydraulic coupling to avoid dynamic overload. The sensor overload protection is very reliable. If you have mining project or chemical plant, the toothed roller crusher is prepared for you in China Fote.
The toothed roll crusher is suitable for crushing raw coal in coal mines, coal preparation plants and other industries (allowing less than 30% of coal gangue in raw coal). The crusher is also used to break other brittle materials whose hardness is similar to that of raw coal.
It has the characteristics of high efficiency, long life, full sealing, low noise, and uniform granularity. The double-toothed roll crusher is equipped with a scraper to keep the groove and working surface clean. For the toothed roll crusher, the outlet-size depends on the gap between the two rollers, the size of teeth, shape of teeth, and the number.
The double-toothed roll crusher is relatively small in volume. It consists of two tooth rolls that are mounted in parallel and rotate in opposite directions. According to the crushing capacity and the size of the discharging granularity, the two crushing rolls are uniformly filled with brushing teeth.
And the double-toothed roll crusher adopts the operation way of non-circular, non-intermesh and non-uniform, which can enhance the contact face of roller teeth, and avoid material slippage and improve crushing efficiency.
When the toothed roller rotates, the teeth on the surface of the roller can bite the materials and crush them. Each roller crusher of the crushing system is driven by a separate motor. The roller crusher is generally driven by a belt, and it constitutes the deceleration system along with the reducing mechanism.
FTM double-tooth roller crusher for sand making, limestone, rock, clay crushing has a good crushing effect on wet and sticky materials. And adherence or clogging phenomenon never occurs during the work.
The silicon-aluminum raw material is an indispensable calibration material in the dry cement production process. After the mining work, the materials need to be crushed, transported and stored. and then they are sent to the raw material mill for grinding according to an appropriate ratio.
However, the silico-alumina raw materials have strong water storage capacity and high plasticity index, especially for bauxite and marlstone with water content more than 17% and plasticity index generally above 15. Because of the viscosity of materials, it can lead to blockage and arching during the process of crushing, transportation and storage, thus affecting the normal operation of the system.
In order to solve the problem of adherence and clogging of wet-adhesive materials in the crushing stage, FTM toothed roll crusher is used to break the mixture of limestone and marl. In detail, firstly, the wet and dry materials are mixed and crushed, and secondly, the wet-adhesive materials and other limestone materials with lower moisture content are mixed into the crusher. And finally, they are crushed according to an appropriate ratio.
The toothed roller crusher machine has advantages of small volume, large crushing ratio, low noise, simple structure, convenient maintenance, high productivity, uniform particle size of crushed material, low crushing rate, convenient maintenance, sensitive overload protection, safe and reliable.
roll crusher manufacturer & design | williams crusher
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Williams is an industry-leading roll crusher manufacturer and designer for high-quality roll crushers with desirable benefits such as high throughput capacity, minimal maintenance requirements, low cost per ton operation, and more. Learn more about our heavy-duty roll crushers below or contact our sales engineers to talk about your application needs.
A combination of impact, shear, and compression are the forces necessary to perform the crushing and size reduction in a Williams roll crusher. The material enters the roll crusher machine and is impacted by the roll as it rotates. Then, as the material is pulled between a crushing plate or rolls, shear and compression forces act upon the material.
The rolls act as flywheels, contributing to smooth operation and efficient use of power. Roll crushing surfaces operate at a fixed distance apart, as opposed to the continually changing distances in a jaw or cone crusher. This creates a more consistent product size.Roll crushers are low in profile and relatively easy to install. They can be fed with a minimum of headroom, or even choke fed. Adjustments are simple andinternal parts are readily accessible.
Typical feed materials for Williams Roll Crushers include: bauxite, cement clinker, chalk, cinders, clay, coal, glass, gypsum, limestone, burnt lime, rock salt, sandstone, shale, sulfur ore, sea shells, and sewer sludge clinker. Single Roll Crushers, sometimes called lump breakers, can also be used for breaking frozen or agglomerated materials.
Williams Roll Crushers are used in a variety of industries such as, mining recycling, and power industries. Interested in learning more about the Williams Roll Crushers for your specific industry and application? Contact our sales engineers!
Choosing between a single roll crusher and double roll crusher depends upon the type of feed material, feed size, product size desired, and consistency of both feed and product.
Both single and double roll crushers operate most efficiently with dry, friable materials. However, single roll machines have been widely and successfully used for the reduction of moist clays. They also have been long used as primary and secondary coal crushers, both at mine sites and power plants, where a minimum of fines is desired.
Williams single roll crushers reduce via a combination of impact, shear, and compression. The rolls are always toothed in patterns suited to the feed material. Single Roll Crushers generally handle larger feed sizes at higher reduction ratios in higher capacities and are particularly well suited to be used as lump breakers.
Double roll crushers reduce primarily through compression, although some shear is obtained with toothed rolls. Rolls for these crushers come in combinations of smooth, corrugated, and toothed designs. Double Roll Crushers produce a finer product at lower reduction ratios and capacities.
Oversized, heat-treated, alloy steel shafts plus self-aligning, roller-type bearings assure long life and maximum use of power. Jackshafts for control of roller speed are standard on double roll crushers, optional on larger Single Roll Crushers.
Heavy-duty compression springs permit movement of floating roll to pass tramp metal and other uncrushables, avoiding overload and damage. Smaller Single Roll Crushers are equipped with a shear pin release.
Faces Tooth patterns and corrugations to fit feed material; abrasion-resistant alloy; easily replaceable.
Ash Crushers have additional features including dust-tight design and sealed cover plates for breaker plate access.
Williams Single Roll Crushers are also available in a 15 inch (381mm) diameter dust-tight version for applications such where it would be expensive to have dust collection air.
Already well known for rugged construction, low profile, high reduction ratio, and economical cost, Williams Dust-Tight Ash Single Roll Crushers also have easy access to the rotor for maintenance.
These dust-tight roll crushers are perfect for applications such as crushing ash, limestone, coal, or glass.
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.
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