Roll crusher in the field of material crushing by virtue of its unique design and working principle, showing a variety of technical Roll crusher advantages. With the core of ‘high-pressure extrusion crushing’, the Roll Crusher has become the preferred equipment in the field of medium and fine crushing through the five advantages of high efficiency and energy saving, precise and controllable particle size, strong adaptability, low maintenance cost and green production. In the fields of sand and gravel aggregate, metal beneficiation, coal pre-processing and resource regeneration, its comprehensive performance is significantly better than traditional crushing solutions. Hydraulic intelligence and wear-resistant material upgrading (such as zirconia composite roll surface), its application boundary will be further expanded. The following is a systematic overview of the core advantages of the crusher in combination with the industry applications and technical characteristics:
Roll crusher
1. High energy efficiency and processing capacity
High Crushing Efficiency
Adopting the extrusion crushing method of double rolls rotating in opposite directions, the materials are instantly crushed under high pressure of 50-200MPa. This direct pressure crushing consumes less energy compared with impact crushing, saving more than 45% of energy consumption under the same capacity, especially suitable for large-scale continuous production scenarios (e.g., mines, sand and gravel aggregate lines), with a processing capacity of 1-400 tonnes/hour.
Low over-crushing rate
The material produced by extrusion crushing has many internal micro-cracks, but the external form remains more intact. The over-crushing rate is significantly lower than that of hammer or impact crusher, and reduces the subsequent grinding energy consumption by 15-30%.
2. Flexibility of crushing size control and product quality
Infinitely adjustable discharge size
Adjust the roll gap (1-50mm adjustable) through the hydraulic system, wedge device or shims. And accurately control the size of the finished product (e.g. 1-5mm sand making, 10-30mm ore dressing feed). Closed loop design (with screening equipment) can further improve the passing rate of particle size.
Uniform and high-quality particle size
produces cubic or regular particles with reasonable grading and low needle and flake content. Which is especially suitable for high grade concrete aggregate and precision sorting process (such as tungsten ore jigging) with strict requirements on particle size.
3. Wide material adaptability
High compatibility of hardness and humidity
Material type: suitable for medium and high hardness materials (limestone, gangue, iron ore) and viscous. High humidity materials (such as clayey shale, tailing sludge).
>Wet and dry: the sealed structure design can deal with dry materials and wet materials with moisture content below 15%, avoiding sticky rollers from clogging.
Special Scenario Expansion
High purity crushing: zirconia rollers are used in quartz sand, lithium ore and other scenes where iron pollution is avoided;
Corrosive environment: alloy steel rollers are resistant to acid and alkali corrosion (e.g., crushing of chemical raw materials and rare-earth ores).
4. Simple structure and convenient maintenance
Modular design
The main structure contains only core components such as rollers, bearings and driving device, with few failure points. Wear-resistant roller skins adopt quick release design (e.g. 20cm thicker high manganese steel roller skins), which can be replaced in just a few hours and have a life span of up to 3 years.
Intelligent maintenance support
Hydraulic models are equipped with automatic overload protection (automatic roll backing out in case of metal foreign objects), and an intelligent system that monitors roll gap wear and bearing temperature in real time to reduce the risk of accidental shutdown.
5. Environmental protection and safety performance
Low noise and dust control
The noise of operation is <80dB (further reduced to below 75dB after the installation of silencer), and with the sealing cover and dust removal system, the dust emission is in line with the national standard.
High operating safety
Hydraulic overload protection prevents hard objects from jamming and damaging the equipment. The electrical system integrates an emergency stop button and supports remote monitoring, realising automated production with ‘one person operation’.
