150-200 T/H Clean Coal Crushing Plant Upgraded with Hydraulic Double Roller Crusher
150-200 T/H Clean Coal Crushing Plant Upgraded with Hydraulic Double Roller Crusher
Project Case Study 150-200 T/H Clean Coal Crushing Plant Upgraded with Hydraulic Double Roller Crusher How Engineering Precision Eliminated Over-Crushing and Wet Material Clogging The Challenge: High Waste Rates & Frequent Clogging Our client, a large-scale coal preparation and chemical ……
- Productive Capacity:4-500t/h
- Finished Product Size:25-200
- Included Equipment:
- Double Roller Crusher
Project Case Study
150-200 T/H Clean Coal Crushing Plant Upgraded with Hydraulic Double Roller Crusher
How Engineering Precision Eliminated Over-Crushing and Wet Material Clogging
The Challenge: High Waste Rates & Frequent Clogging
Our client, a large-scale coal preparation and chemical plant, was previously using a traditional hammer mill to process raw coal for thermal boiler feeding. However, they faced two critical bottlenecks that severely impacted profit margins:
Severe Over-Crushing: The impact action of the hammer mill generated over 25% coal powder (fines under 3mm), which burned too quickly and caused massive economic loss.
Moisture Clogging: During the rainy season, raw coal moisture soared to over 12%, completely choking the crushing chamber and forcing shutdowns every few hours for manual cleaning.
Complete View of the Coal Crushing Plant Site
The Solution: 2PGY1500×1200 Large Hydraulic Roller Crusher
After diagnosing the material properties, our technical team configured the 2PGY1500×1200 Fully Hydraulic Double Roller Crusher with customized high-chromium alloy roller shells.
Unlike impact crushing, the counter-rotating rollers utilize low-speed, high-torque static pressure extrusion. The raw coal is drawn smoothly between the rollers, crushed instantly along its natural fractures, and discharged cleanly via gravity.
Complete View of the Coal Crushing Plant Site
The Results: 30% Energy Savings & Optimized Particle Size
Since commissioning, the plant has achieved stable 24/7 continuous operation with remarkable performance improvements:
✔ Fines Generation Dropped Below 5%
The over-crushing rate dropped from 25% to under 5%, significantly increasing the output value of high-premium sized coal.
The over-crushing rate dropped from 25% to under 5%, significantly increasing the output value of high-premium sized coal.
✔ Zero Wet Material Clogging
Even during heavy rain and processing 12%+ high-moisture coal, the continuous self-cleaning movement of the dual rollers completely prevented sticking.
Even during heavy rain and processing 12%+ high-moisture coal, the continuous self-cleaning movement of the dual rollers completely prevented sticking.
✔ 30% Direct Power Savings
The intelligent automatic hydraulic system drastically optimized electricity consumption, saving thousands of dollars in monthly utility bills.
The intelligent automatic hydraulic system drastically optimized electricity consumption, saving thousands of dollars in monthly utility bills.
Want to Achieve Similar Efficiency for Your Plant?
Contact our senior engineers for a free layout design and customized quotation based on your raw coal specs.
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