Double Roll Crusher
The Double Roll Crusher uses two counter-rotating toothed or smooth rolls to compress and shear material into uniform particles. This crusher excels at producing precisely sized, low-fines output from brittle materials, making it ideal for coal, coke, chemical raw materials, and fertilizer production. The roll crusher's low-speed operation generates minimal dust and noise, and the adjustable roll gap provides precise control over output particle size. Its gentle crushing action also makes it suitable for processing materials where over-crushing must be avoided.
Working Principle
Two rolls rotate in opposite directions. Material is drawn into the gap between rolls by friction. The rolls compress material, reducing it to the gap width. Smooth rolls crush by compression; toothed rolls combine compression with shearing for more effective breaking of slabby materials. The roll gap is adjustable, controlling output particle size.
The grinding process is precisely controlled by the integrated classification system, which separates qualified fine powder from coarse particles. Coarse particles fall back to the grinding chamber for regrinding, while fine powder is conveyed by airflow to the cyclone collector and then to the finished product silo. This closed-circuit design ensures consistent product quality and high grinding efficiency.
Key Features & Advantages
Precise Output Size
Roll gap is precisely adjustable, providing accurate control over output particle size with minimal fines.
Low Dust and Noise
Low-speed compression crushing generates minimal dust and noise, creating a cleaner working environment.
Gentle Crushing
Compression action avoids over-crushing, ideal for applications where preserving particle size range is important.
Versatile Roll Surfaces
Available with smooth, toothed, or corrugated roll surfaces for different material characteristics and product requirements.
Applications & Industry Use
This equipment is widely used across multiple industries for various powder processing applications:
- Coal crushing for power plants
- Coke crushing
- Chemical raw material processing
- Fertilizer material crushing
- Limestone fine crushing
- Glass cullet processing
Processable Materials
The versatile design of this equipment allows it to process a wide range of non-metallic minerals and industrial materials. Below are some of the most commonly processed materials. For detailed grinding solutions for each material, please visit our materials page.
Technical Specifications
The following table provides detailed technical parameters for each model in this product series. These specifications are based on standard configurations and may vary depending on material properties and specific application requirements. Contact our engineering team for customized configurations.
| Model | 2PG-400 | 2PG-600 | 2PG-900 | 2PG-1200 |
|---|---|---|---|---|
| Roll Dia (mm) | 400 | 600 | 900 | 1200 |
| Max Feed (mm) | 25 | 40 | 60 | 80 |
| Output (mm) | 2-8 | 2-10 | 2-15 | 2-20 |
| Capacity (t/h) | 5-15 | 15-40 | 30-80 | 60-150 |
| Power (kW) | 5.5x2 | 18.5x2 | 30x2 | 55x2 |
Performance & Efficiency
The Double Roll Crusher is designed for maximum grinding efficiency and energy savings. The optimized grinding chamber geometry, combined with high-precision classification, ensures that energy is used effectively for particle size reduction rather than wasted on over-grinding or heat generation. Compared to conventional milling systems, our equipment typically achieves 20-30% lower power consumption per ton of finished powder.
Key performance metrics include stable fineness control with deviation less than 5%, low noise levels below 75 dB at 1 meter distance, and dust emissions below 20 mg/m3 when equipped with our pulse bag filter system. These performance characteristics make our equipment suitable for even the most demanding industrial environments and stringent environmental regulations.
Installation & Commissioning
Proper installation is critical for optimal equipment performance and longevity. Our experienced engineers provide on-site installation and commissioning services, including equipment positioning, alignment, electrical connection, piping installation, and system integration. The typical installation timeline ranges from 15 to 45 days depending on equipment model and production line complexity.
During commissioning, we conduct comprehensive performance tests including no-load test, load test, and production trial runs. We verify all performance parameters meet design specifications, calibrate control systems, train your operators on proper operation and maintenance procedures, and deliver a complete commissioning report with all test data.
Frequently Asked Questions
Smooth rolls are for fine crushing of brittle materials where minimal fines are desired. Toothed rolls are for primary crushing of slabby or larger materials. We can advise based on your specific material and requirements.
Output size is primarily controlled by the gap between the rolls. Hydraulic or mechanical gap adjustment allows changes within seconds. Smaller gaps produce finer output but lower capacity.