Roll Crusher

What is Roll Crusher Machine?

Roll crusher is also called double roll crusher, double teeth roll crusher, etc. The surface of the roller crusher is made of high manganese steel, which can stand up to heat treatment.

A Roll Crusher, also known as a roller crusher, is a machine that uses compression to crush materials. Imagine squeezing something between two heavy, spinning cylinders—that’s the basic idea. Material is fed into the gap between the rolls. The spinning rolls grab the material and pull it through, crushing it to a predetermined size. Its main job is to create a very uniform final product, making it a sizing machine more than just a simple reduction machine.

What are Benefits of Roll Crusher?

The main advantage of a roll crusher is its ability to produce a consistent product with minimal fines. Unlike impact crushers that shatter rock, a roll crusher applies slow, high pressure. This breaks the material along its natural weak points without creating extra dust or stress fractures. A double roll crusher in particular gives you excellent control over this process. This means you get a stronger, more stable aggregate, which is perfect for high-quality blocks.

Another key benefit is its ability to handle difficult materials.

• Wet & Sticky Materials: It is excellent for crushing things like wet clay or shale.
• Friable Materials: It works well for brittle materials like coal or sintered clinker.
• Energy Efficiency: It uses less power compared to other crusher types for the same job.

What are the Functions of Roll Crusher?

1.Crushing various rocks

Double toothed roller crusher is generally used for crushing medium-hard rocks with compressive strength of less than 200 Mpa, such as limestone phosphate, basalt, granite, river pebbles, iron ore, gold ore, copper ore lead-zinc ore, nickel ore, asphalt, bricks, cement, and other materials.

2. The first choice for crushing coal

Double toothed roller crusher is a new type of equipment recommended by major coal plants for crushing raw coal, coke, lignite, and activated carbon. lt crushes the coal by squeezing the double toothed rollers and easily removes the materials adhering to the rollers.

The roller crusher has dual functions of pre-screening and crushing. Small and medium-sized materials in the coal mine are directly leaked from the gap between the toothed rollers to avoid reprocessing. The phenomenon of over-crushing is improved.

3.Crushing sticky materials

Roller Crusher Classification

Roll crushers come in a few main configurations, designed for different tasks. The choice depends on your material and the reduction ratio you need.

• Single Roll Crusher: This type has one spinning roll that crushes material against a solid plate. It’s often used as a primary coal crusher.
• Double Roll Crusher: This is the most common type. This double roller crusher uses two counter-rotating rolls that pull material between them for superior size control.
• Toothed Roll Crusher: The rolls on this tooth roller crusher have teeth designed to grab and shred sticky materials. This makes it a perfect Roll Crusher for Clay.
• Smooth Roll Crusher: The rolls are smooth and used for fine crushing of brittle, non-slippery materials.

Our company produces 3 types of roll breakers: Roller crushers,Toothed rollers and hydraulic rollers.

Roll Crusher

Toothed Roll Crusher

Hydraulic Roller Crusher

How Does the Roller Crusher Work?(Roller Crusher Workprinciple)

The crusher working principle is simple but precise. Material is fed into the top of the machine. The rotating rolls create a “nip angle.” This is the angle where the rolls grip a particle. If the particle is the right size, the rolls pull it into the gap. The immense pressure from the crush roll action breaks the particle. The crushed material then falls out of the bottom of the machine.

The key to high efficiency is feeding the crusher correctly. The feed material must be small enough for the rolls to “bite.” If the feed is too large, the machine will not be able to grip it and will spit it back out. This is why controlling the size of the material going into the crusher is so important.
The main working parts of the roller crusher is the cylindrical rollers. The rollers are supported by the fixed and movable bearings, and they are relatively rotating which are driven by the motor. The materials are crushed by the friction of the rotating rollers, and the finished products are discharged from the gap of the rollers.

The Roller Crusher Key Applications

The roller crusher, also known as roll crusher machine, has a wide range of applications across various industries.

Roll Crusher is suitable for River gravel, iron ore, limestone, basalt, quartz, granite and other medium or hard ores and rocks in metallurgy industry, cement industry, power department, construction, phosphate, refractory industry, etc.

The Structure of the Roll Crusher?

A mining crusher like this is built to be tough. At ZONEDING, we focus on a robust structure to ensure long life and reliable operation.

• Frame: A heavy-duty steel frame that holds everything together.
• Rolls: One or two heavy cylinders. This crush roller is the main working part and is covered in a replaceable, wear-resistant shell.
• Bearings: Heavy-duty bearings that support the rolls and allow them to spin under extreme pressure.
• Gap Adjustment System: A system of shims or hydraulics that allows you to set the distance between the rolls, controlling the final product size.
• Drive System: A motor, gearbox, and belts or chains that turn the rolls.
• Spring Protection System: A powerful spring pack that allows one of the rolls to move if an uncrushable object (like tramp metal) enters the crusher. This protects the machine from catastrophic damage.

Roll Crusher Several Structural Advantages That Contribute

The counter-roller crusher pulls the material on the roller surface into the crushing cavity, so that the material is crushed by the stress mainly caused by squeezing, and is taken out of the crushing cavity by the rotating roller and discharged as the crushed product.

General Specification

Product Features & Advantage

 

① It has a simple and compact structure with small occupation and convenient operation and maintenance.

② The cost is low and the operation is stable, with high energy and crushing efficiency, and adjustable discharge port.

③ It has a light weight, small size, significantly saving investment.

④ The roller crusher is equipped with safety protection devices. When metal pieces enter the crushing chamber, the protective device works and lets the metal leak out of the machine without stopping it.

⑤ The inside is equipped with dustproof board, which has good sealing performance, avoids splashing of fine materials after crushing, with less dust, low working noise,  largely improving the working environment.

⑥ The gap of the abrasive roller can be adjusted arbitrarily between 1mm and 20mm. After adjusting the roll gap according to the requirements, the crushing particle size can be reliably controlled, and all of them are discharged from the lower part of the crushing cavity with the ideal size.

The roller crusher is working in low speed and high pressure with extruding materials which fall vertically into the crushing chamber from the upper part, and are crushed by the strong pressure generated between the two rolls.

⑦ Most of the material has become powdery, and a large number of cracks have been generated in the interior of the small granular material. Thus, in the further pulverization process, the grinding energy consumption can be greatly reduced and the yield can be increased.

⑧ The roller crusher is equipped with a replaceable wear-resistant lining plate which adopts domestic advanced technology, and has the advantages of long service life, easy damage and convenient maintenance.

The continuous service life can be more than one year, and can be easily changed when the wear is seriously damaged. The maintenance quantity is small and the cost is low, which is unmatched by other types of crushers.

What are Features of Roll Crushers from ZONEDING?

When we design our roll crushers, we focus on reliability and low operating costs for you. Our machines are built with features that make a real difference in your daily operations. The roll shells we use are made from a high-manganese steel alloy for excellent wear life. We also offer hard-facing options to rebuild the roll surface, which can extend its life by up to 500%.

Our spring protection system is another key feature. It acts as a mechanical fuse. We use oversized, durable springs that are easy to inspect and tension. This system is crucial for protecting your investment from damage caused by tramp metal. A reliable protection system means you have less downtime and fewer expensive repairs.

What Materials Can a Roll Crusher Effectively Handle?

These versatile roll crushers excel with certain types of materials. They are not the best choice for very hard, abrasive rock like granite. They shine when crushing soft to medium-hard materials.

• Coal: As effective coal crushers, the Coal Roll Crusher is an industry standard for sizing coal with minimal dust.
• Clay, Shale, Marl: A tooth roller crusher is the best machine for preparing wet, sticky clays for brick making. It crushes, mixes, and de-agglomerates in one step.
• Limestone: It can be used for secondary crushing of limestone for aggregate production.
• Glass: It can crush glass into a consistent cullet size for recycling.
• Fertilizer and Salt: It is used to break up clumps and produce a granular product.

How Much Price of the Roll Crusher Cost?

The Roll Crusher Price can vary widely, from around $10,000 for a small laboratory model to over $150,000 for a large, high-capacity mine crusher. The final cost for your specific roll crusher depends on several factors:

• Size and Capacity: Larger machines with higher throughput cost more.
• Roll Type: Custom toothed or corrugated rolls are more expensive than smooth rolls.
• Brand and Quality: Well-known brands with heavy-duty construction demand a higher price.
• Motor and Drive: The size of the motor and the type of drive system will affect the cost.

Remember, the purchase price is only part of the total cost. The ongoing cost of wear parts and maintenance is also a major factor.

Smooth vs. Toothed: Which Roll Crusher is Right for You?

Choosing between a Smooth Roll Crusher and a toothed one depends entirely on your material. Using the wrong type will lead to poor performance and high costs.

• Choose a Smooth Roll Crusher if:
  • Your material is brittle and not slippery, like coal or sintered clinker.
  • You are doing tertiary or fine crushing to produce sand.
  • Your main goal is to create a consistent granular product with the fewest possible fines.
• Choose a Toothed Roll Crusher if:
  • Your material is plastic, sticky, or wet. This makes it the ideal Roll Crusher for Clay, shale, or mudstone.
  • You need to grab and tear apart large clumps of material.
  • You are doing primary or secondary crushing of softer materials.

When to Choose a Roll Crusher Over a Jaw or Cone Crusher?

These three crushers do different jobs. Choosing the right one is critical for an efficient plant.

• Choose a Jaw Crusher for: Primary crushing of very large, hard rock. It is a coarse crusher.
• Choose a Cone Crusher for: Secondary and tertiary crushing of hard, abrasive rock. It is very efficient at producing cubical aggregate from materials like granite and basalt.
• Choose a Roll Crusher when:
  • Your top priority is minimizing fines.
  • You are crushing soft, sticky, or friable materials.
  • You need precise control over the top size of your final product.

How Do You Adjust the Gap to Control the Final Product Size?

Controlling your final product size is easy with a roll crusher. The distance between the two rolls is called the “gap.” This gap setting directly determines the maximum size of the material that comes out. You can adjust this gap using a simple system of shims. You add or remove these metal plates to move one of the rolls closer to or farther from the other. Some more advanced models use a hydraulic system that allows for faster and easier adjustments.

What are the Main Wear Parts of Roll Crushers?

Like any crusher, a roll crusher has parts that wear out over time and need to be replaced. The main wear parts are:

• Roll Shells: The outer surface of the crush roll takes all the abrasive wear. These are designed to be replaced or rebuilt.
• Bearings: The heavy-duty bearings can wear out over time, especially if not lubricated properly.
• Drive Components: Belts and gearboxes need regular inspection and maintenance.

The roll shells are the most significant wear cost. Proper maintenance and operation can greatly extend their life.

What is the Maintenance for a Roll Crusher?

Good maintenance is the key to long life and low operating costs. There are a few critical tasks.

1. Lubrication: Regularly grease the bearings according to the manufacturer’s schedule. This is the single most important task.
2. Check the Gap: Regularly measure the gap to ensure it hasn’t changed, which would affect your product size.
3. Test the Protection System: Once a quarter, you must test the spring pack or hydraulic system to ensure it moves freely. A seized system provides no protection.
4. Hardfacing the Rolls: The smartest way to manage wear costs is to have a regular schedule for hardfacing. This is a welding process that rebuilds the roll surface with a highly abrasion-resistant material. It is much cheaper than replacing the entire roll shell.

Why Choose ZONEDING?

At ZONEDING, we have been building block machines and crushing equipment since 1990. We don’t just sell machines; we provide complete, reliable solutions. And We understand that a crush roller is part of a larger system. Our engineers will help you choose the right double roll crusher for your material and integrate it into your production line. We build our roll crushers with heavy-duty frames, superior wear parts, and reliable protection systems to ensure you get consistent performance day after day. Our goal is to be your partner, providing the equipment and expertise you need to succeed.

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ZONEDING has exported crushing plants in 100+ countries, providing customers with versatile and ideal crushing plant solutions.