Heavy-Duty Double Roller Crusher with Low-Speed High-Torque, Self-Cleaning

Product Specification

1.Product Introduction

The heavy-duty double roller crusher with low-speed high-torque operation is an advanced comminution machine purposefully engineered for the demanding environment of coal preparation plants. Its design focuses on processing high-volume streams of raw coal, middlings, and associated shale or clay parting material. Operating at low rotational speeds with exceptional torque, the crusher delivers highly efficient size reduction while minimizing the generation of unusable coal fines and dust. To address the severe clogging risks common to wet, sticky, or clay-rich coal, the equipment features an integrated system of self-cleaning scraper bars. Supported by a responsive hydraulic accumulator relief system, this crusher offers unmatched reliability, safety, and operational continuity when handling variable feed compositions.

2.Application

This specialized crusher is primarily deployed in the primary and secondary crushing stages of coal preparation plants, thermal power stations, coking facilities, and coal-to-chemical operations. It effectively processes run-of-mine (ROM) coal, lignite, bituminous coal, anthracite, and highly abrasive coal gangue. The machine is exceptionally well-suited for regions experiencing high precipitation or handling high-moisture coal deposits, where traditional crushers frequently suffer from packing, plugging, and catastrophic material bridging. Additionally, its strict control over product top-size makes it an essential pre-treatment unit for feeding downstream screening and heavy-media separation circuits.

3.Working Principle

The operation is driven by independent low-speed, high-torque motors that rotate two heavy-duty rollers toward each other at managed velocities. Coal is fed into the top of the crushing chamber, where the high-torque roller profiles grab the large lumps, pulling them through the fixed gap. Size reduction occurs primarily through high-torque shearing and compression, fracturing the coal along its natural bedding planes. To maintain uninterrupted flow when processing sticky material, automated self-cleaning scraper bars continuously shave off material adhering to the roller surfaces. When uncrushable materials like tramp iron enter the chamber, the hydraulic accumulator relief system instantly compresses to allow the movable roller to back away, discharging the object safely before a nitrogen-charged accumulator automatically snaps the roller back to its original gap setting.

4.Advantages

 Low-speed high-torque efficiency: The high-torque, low-velocity drive configuration maximizes mechanical cutting and shearing power while drastically reducing the generation of fine coal dust and unwanted slimes, optimizing the yield of premium sized coal. Self-cleaning scraper bars: Heavy-duty, wear-resistant scraper bars are positioned dynamically against the roller surfaces, continuously clearing mud, clay, and wet coal buildup to eliminate clogging and maintain a consistent processing capacity. Advanced hydraulic accumulator relief system: Employs a rapid-response hydraulic system backed by nitrogen accumulators, providing instantaneous uncrushable material bypass and automatic positioning resets, which completely prevents structural overload and drivetrain damage. Robust and flexible processing capacity: The extra-heavy-duty chassis and reinforced bearing housings easily absorb the high shocks associated with crushing large partings and dense coal gangue, maintaining a steady throughput under full-load conditions. Low energy consumption and stable operation: Operating at lower speeds inherently reduces power draw during idle periods and lowers structural vibration, resulting in a low kilowatt-per-ton operating cost and an exceptionally long mechanical service life. Convenient operation and maintenance: Features a highly modular framework allowing for rapid replacement of individual tooth segments or scraper assemblies, along with split bearing housings that simplify onsite maintenance without complete machine disassembly. High intelligence and automation: Integrated with a central PLC automation unit that tracks roller speed, torque fluctuations, hydraulic accumulator pressure, and bearing temperature, enabling real-time remote monitoring, automatic reversal cycles to clear minor jams, and seamless integration into plant-wide SCADA systems. Optimized structural design: Designed with a low-profile, compact footprint that allows for easy retrofitting into existing coal handling systems, complemented by a specialized internal geometry that ensures uniform material distribution across the entire roller width.