double tooth roll crusher

Double Tooth Roll Crusher overcomes the limitations of conventional crushers. When traditional impact or jaw crushers process wet coal gangue, bauxite, or clay-rich ores, fine particles tend to adhere to the crushing chamber and screen openings, causing severe clogging, motor overload, and frequent shutdowns for cleaning. These issues not only reduce plant availability but also increase labor costs and risk of equipment damage.

Our double roll crusher operates at low speed with high torque, using a self-cleaning geometry. The specially spaced elements tear and shear the material without compacting it against solid surfaces, so wet fines fall away naturally. This design keeps the crushing cavity clear even at 30% moisture content. As a result, the equipment runs continuously without manual intervention, reduces energy waste from idle running, and extends the service life of wear parts by eliminating repeated impact shock. Production downtime is cut by more than 50%, while the product particle shape remains cubical and suitable for downstream screening or jigging.

Beyond clogging prevention, the double roll crusher delivers several other key benefits for operations handling wet, sticky materials:

1. Low Fines Generation – The shear‑dominated action keeps -6 mm fine powder below 15%, which is critical for downstream jigging or heavy media separation. Excessive fines would otherwise hinder stratification and reduce recovery of valuable components such as sulfur in coal gangue or aluminum in bauxite.

2. Customizable Tooth Profiles – Depending on feed size and hardness, users can select from wolf teeth (for large lumps up to 1050 mm), wave teeth (for medium-sized feed), or sharp teeth (for finer discharge). The roll segments can be replaced individually without removing the entire roll assembly, cutting maintenance time by approximately 70%.

3. Reliable Overload Protection – Integrated hydraulic or spring systems detect uncrushable objects such as tramp iron, rock bolts, or hard boulders. The roll gap instantly widens to let the object pass, then automatically resets to the preset position. This protection mechanism prevents roll breakage and gearbox damage, ensuring zero unplanned downtime.

4. Energy Efficiency – Low-speed operation (typically 50–90 RPM) consumes 15–25% less energy per tonne compared to high-speed impact crushers. The direct drive through twin motors and reducers eliminates power loss from belts or chains, further reducing operational expenses.

5. Wide Application Range – The double roll crusher has proven effective in coal preparation plants (for raw coal and gangue), bauxite mines (for sticky clay‑rich ore), construction waste recycling (for concrete with rebar), and industrial mineral processing (for potash, phosphate, and gypsum). It handles feed sizes from 80 mm to 1050 mm and discharge from 10 mm to 80 mm.

Field data from a coal gangue processing plant in Guizhou shows that after replacing a hammer crusher with this double roll crusher, monthly downtime for cleaning dropped from 18 hours to less than 2 hours, and the yield of -6 mm fines decreased from 28% to 12%. The plant also saved approximately 120,000 kWh annually due to lower motor loads.

For operators struggling with wet, sticky feed materials, the double roll crusher offers a proven, low-maintenance path to higher throughput, better product quality, and lower cost per tonne. Its self-cleaning geometry, robust construction, and field‑proven reliability make it a preferred choice for medium‑hard and adhesive ores worldwide.