Roll Crusher

What is the Roll Crusher?

A roll crusher reduces medium-hard, brittle material between two counter-rotating cylinders. It produces a relatively uniform product with limited dust and is used for ores, coal and minerals in routine laboratory sample preparation.

Overview

A roll crusher passes material between two hardened cylinders that rotate toward each other, drawing the feed into the gap and crushing it by compression. The gap between the rolls sets the product size, and smooth or toothed rolls suit different materials. Because the feed is drawn in and crushed once, the product is comparatively uniform with less fines than impact crushers, and dust generation is reduced. Roll crushers handle medium-hard and brittle materials such as coal, coke, limestone and ores, and are used in laboratory and pilot scale. Roll wear, gap setting and feed uniformity mainly determine performance.

How does it work?

Crushers apply mechanical forces that exceed the strength of the feed material, causing it to fracture. Jaw crushers press material between a fixed and a moving jaw, roll crushers draw it between counter-rotating cylinders, cone crushers squeeze it in a gyrating chamber, hammer crushers strike it with rotating hammers, and impact crushers break it against a rotating or fixed anvil. The reduction ratio, feed size and product size depend on the machine geometry, the gap setting and the material hardness. Crushing is normally the coarse stage that prepares feed for a mill, and over-crushing is avoided because fines can complicate later handling. Wear parts are made from hardened steel or manganese alloys to resist abrasion.

What are the key features?

• Two counter-rotating hardened rolls
• Adjustable gap for controlled product size
• Uniform product with limited fines
• Smooth or toothed roll options
• Compact laboratory and pilot scale designs

What are the technical specifications?

A typical roll crusher configuration offers max feed size of 30 mm, product size of 0.5–5 mm, adjustable, roll diameter of 200 mm, throughput of Up to 300 kg/h, roll material of Hardened alloy steel and roll surface of Smooth or toothed. Values are indicative of the product class; the exact figures for each configuration are confirmed on the quotation and the calibration documents supplied with the instrument.

Which applications is it used for?

The Roll Crusher is used in coal and coke sample preparation, limestone and mineral crushing, ore sample reduction and intermediate stage before fine milling. Across the wider Crushers class, laboratories also deploy it for mining and ore sample preparation, cement and clinker analysis and geological and soil sample reduction.

Which standards and certifications apply?

Relevant standards and methods include ISO 3310-1, ASTM E11, ISO 2591-1, IEC 61010-1 and ISO 6497. Certification candidates for this model are CE and ISO 9001 manufacturing; each is to be confirmed for the specific configuration before shipment, and certificates are supplied only where they have been issued.

Install crushers on a firm floor with the necessary electrical protection and, where required, dust extraction and noise enclosure. Do not exceed the rated feed size, since oversized pieces can jam the machine or damage the jaws. Feed material gradually and avoid running the crusher empty for long periods. Check and replace wear parts on schedule, and clean thoroughly between samples to avoid cross-contamination, using a blank or quartz flush where trace analysis demands it. Follow lock-out procedures during maintenance and guard all moving parts.

How do I select the right Roll Crusher?

Select a roll crusher for medium-hard brittle material where a uniform product and reduced dust are important. Confirm the roll gap range gives the required product size and that the roll surface suits the material. In an RFQ state feed size, product size, throughput, roll material and whether smooth or toothed rolls are needed.

How does it compare with other Crushers variants?

Choose a crusher according to the feed size, hardness and abrasiveness of the material and the required product size. Jaw crushers suit hard, brittle lumps and give a fairly uniform product with adjustable gap. Roll crushers suit medium-hard, brittle material and produce less dust. Cone crushers handle high throughput of hard material. Hammer and impact crushers suit softer, less abrasive materials and give higher reduction ratios. Confirm that the feed opening accepts the largest pieces, that the reduction ratio matches the required downstream size, and that the crushing chamber and wear parts suit the abrasiveness. Consider dust control, sample representativeness and cleaning between samples.