Double Roller Crusher

The 2PG Series is specifically designed for materials with Mohs hardness below 7 and compression strength up to 150 MPa. It efficiently processes coal (all types), limestone, gypsum, salt, clay, shale, and similar medium-soft materials. The crusher particularly excels with brittle, layered, or fibrous materials that benefit from the compressive crushing action rather than impact. Materials with moisture content up to 15% can be effectively processed without clogging issues, as it's less sensitive to wet and sticky materials compared to other crusher types. The versatile design allows for larger feed sizes, making it an optimal primary crusher for soft and medium hard rocks. It's not recommended for highly abrasive materials or extremely hard minerals exceeding 150 MPa, as these require specialized crushing solutions.

The double roller crusher offers distinct advantages in specific applications: 1) More precise product size control with minimal overgrinding compared to hammer crushers; 2) Lower power consumption per ton (15-25% less than hammer crushers); 3) Significantly less dust and noise generation; 4) Better performance with layered or brittle materials; 5) Lower headroom requirements for installation. However, jaw crushers handle harder materials and larger feed sizes, while hammer crushers achieve higher reduction ratios. The double roller crusher is preferred when product size consistency, energy efficiency, and gentle crushing action are priorities, especially for coal, limestone, and clay materials where maintaining particle structure is important for downstream processes.

Optimal performance requires a structured maintenance program: 1) Daily inspection of roller surfaces, gap settings, and material buildup; 2) Weekly lubrication of bearings and drive components according to the lubrication chart; 3) Monthly inspection of seals, hydraulic system pressure, and alignment verification; 4) Quarterly comprehensive inspection and preventive component replacement. Roller inspection or replacement interval varies by material: limestone (500-800 hours), coal (800-1200 hours), and clay (300-600 hours). The simplified access design allows roller inspection without complete disassembly, reducing maintenance downtime by up to 60% compared to traditional designs. We recommend stocking commonly replaced wear parts to minimize operational interruptions during scheduled maintenance.

Performance optimization involves several key adjustments: 1) Set the proper gap distance based on desired product size and material characteristics (typically 1/10 to 1/6 of roller diameter for optimal efficiency); 2) Select appropriate roller surface patterns (smooth, corrugated, or toothed) based on material properties - toothed for coal and soft materials, corrugated for medium-hard materials, and smooth for brittle materials; 3) Maintain consistent feed distribution across the entire roller width for uniform wear and maximum throughput; 4) Adjust feed rate to maintain 70-80% of maximum capacity for optimal energy efficiency; 5) Consider material moisture content - slightly dampen very dry materials to reduce dust and improve compression; 6) Monitor power draw to prevent overloading; 7) Maintain proper tensioning on drive systems. These adjustments can increase throughput by 10-20% while reducing specific energy consumption.

Selection depends on several application-specific factors: 1) Material properties - hardness, abrasiveness, moisture content, and crushing characteristics; 2) Production requirements - desired capacity, feed size, and target product size; 3) Installation constraints - available space, headroom limitations, and foundation capabilities; 4) Operational considerations - continuous vs. intermittent operation, dust containment requirements, and noise restrictions; 5) Economic factors - initial investment, operational costs, and expected return on investment. The roller diameter primarily determines the maximum feed size (approximately 1/20 to 1/15 of roller diameter), while roller length determines capacity. For optimal production capacity, factors to consider include: compressive strength of crushed material (≤120 MPa), surface moisture (≤2%), material density (around 1.6 t/m³), and continuous, even feeding across the full roll length. With these conditions met, the qualification rate of discharge particle size should reach ≥80%.

The 2PG Series delivers multiple benefits specifically for coal processing: 1) Controlled compression crushing that preserves coal structure and reduces fines generation by 25-40% compared to impact crushers; 2) Adjustable gap settings allowing rapid response to changing coal characteristics or quality requirements; 3) Effective handling of wet or slightly sticky coal with specialized tooth designs that prevent material buildup; 4) Lower power consumption per ton, typically 0.3-0.6 kWh/t depending on coal type; 5) Reduced dust generation through gentle crushing action and effective sealing, improving environmental compliance; 6) Precise product sizing critical for power generation efficiency and coking coal applications; 7) Ability to handle foreign materials through overload protection systems without catastrophic failure; 8) Lower maintenance costs with replaceable wear segments rather than complete roller replacement. These benefits make it particularly valuable for both mining operations and power plants requiring consistent coal sizing.

The hydraulic adjustment system utilizes precision hydraulic cylinders to position the movable roller, maintaining exact gap settings under varying load conditions. In case of overload incidents, the system reacts by retracting one roll and letting tramp metal or overloading material pass through the gap. This dramatically reduces the need for personnel to enter the crushing chamber, ensuring greater operator safety and reducing downtime. The system includes: 1) Dual-acting hydraulic cylinders with position feedback; 2) Accumulator-based pressure compensation that maintains consistent crushing force; 3) Overload relief valves that automatically protect against uncrushable objects; 4) Digital control interface for precise gap adjustments. Maintenance requirements include: 1) Monthly hydraulic fluid level and quality checks; 2) Quarterly inspection of seals and connections for leakage; 3) Annual hydraulic oil replacement and system flushing; 4) Biennial replacement of accumulator bladders and pressure sensors. When properly maintained, the hydraulic system typically provides 5+ years of reliable operation before requiring major overhaul.

The 2PG Series offers extensive customization: 1) Roller surface patterns including smooth, corrugated, toothed, and hybrid designs optimized for specific materials; 2) Wear-resistant materials ranging from standard alloy steel to tungsten carbide inserts for highly abrasive applications; 3) Drive arrangements including direct-coupled, V-belt drive options to match specific operational requirements; 4) Feed and discharge arrangements tailored to existing plant layouts; 5) Control systems ranging from basic manual controls to fully automated operation with remote adjustment capability; 6) Dust containment systems from standard seals to negative pressure enclosures for hazardous materials; 7) Special corrosion-resistant materials for chemical processing applications; 8) High-temperature modifications for pre-heated materials; 9) Custom roller width-to-diameter ratios for specific capacity and sizing requirements. The same specification double roll crusher can form a series of products with different production capacity to meet the requirements of different users according to the standard discharge size range.

The 2PG Series delivers significant sustainability benefits: 1) Energy efficiency - 15-25% lower specific power consumption (kWh/ton) compared to equivalent capacity hammer or impact crushers through direct compression rather than impact crushing; 2) Reduced dust generation - up to 85% less airborne particulates through controlled compression and effective sealing; 3) Lower noise emissions - typically 78-85dB compared to 95-105dB for impact crushers; 4) Extended component life - precision-engineered wear components last 50-80% longer, reducing resource consumption and waste generation; 5) Precise material sizing - minimizes overgrinding and reduces energy consumption in downstream processes; 6) Smaller installation footprint - compact design requires less construction material and space; 7) Lower water usage - dry processing eliminates need for water in dust suppression. These factors combine to reduce the overall environmental footprint while improving operational economics, supporting both sustainability goals and regulatory compliance for modern processing operations.