Huashengming Double Roll Crusher Eliminates Clogging for a Coal Gangue Processing Plant

Customer Profile

A coal preparation plant in Southwest China processes large volumes of run-of-mine coal gangue. The material has a naturally high moisture content (25-30%) and contains significant clay fines.

The Challenge

The plant originally used a hammer crusher for primary and secondary crushing. However, the high moisture and sticky nature of the gangue caused severe clogging:

Frequent shutdowns – The hammer crusher clogged every 2-3 hours, requiring manual cleaning.

Low availability – The plant operated at less than 65% of its scheduled time due to cleaning stoppages.

High maintenance costs – Hammers and impact plates wore out rapidly, and labor costs for clearing blockages were substantial.

Poor downstream performance – Over‑crushing generated excessive fine powder, negatively affecting subsequent jigging separation.

The plant needed a reliable, clog‑free crushing solution that could handle wet, sticky gangue continuously.

Coal gangue to be crushed by double roll crusher

The Solution

After evaluating several options, the plant replaced its hammer crusher with a Huashengming Double Roll Crusher (model 2PGC900×900).

Key features of the selected solution:

Screen‑less design – No grate bars or screens to blind.

Self‑cleaning tooth geometry – Specially spaced teeth tear and shear the material; wet fines fall away naturally.

Low‑speed, high‑torque operation – Runs at approximately 70 RPM, minimizing fines generation.

Hydraulic overload protection – Automatically widens the roll gap when tramp iron enters, then resets without stopping the machine.

Segmented roll discs – Worn tooth segments can be replaced on site without removing the entire roll assembly.

Huashengming engineers also provided on‑site installation guidance and operator training.

Double roll crusher at the production site。

The Results

After the double roll crusher was commissioned and put into continuous operation, the plant achieved significant improvements:

Zero clogging – The crusher has run for months without a single cleaning stoppage. Wet fines fall away naturally, keeping the crushing chamber clear even at 30% moisture.

Higher plant availability – Operating rate increased substantially, allowing the plant to meet production targets reliably.

Reduced maintenance – No hammers or impact plates to replace. Roll shell wear is minimal; periodic inspection is quick and simple.

Better product quality – Fines (-6mm) content dropped noticeably, improving downstream jigging efficiency and pyrite recovery.

Lower operating costs – Maintenance labor and spare parts consumption were sharply reduced.

Customer Feedback

“We used to dread rainy seasons because our hammer crusher would clog every few hours. Now with the Huashengming double roll crusher, the machine runs 24/7 without a single blockage. It has completely changed our operation – less downtime, lower cost, and better recovery.”

— Plant Manager, Guizhou Coal Preparation Plant

Double roll crusher crushing coal gangue

Conclusion

For plants processing wet, sticky materials like coal gangue, bauxite, or shale, the Huashengming Double Roll Crusher offers a proven, low‑maintenance solution. Its screen‑less design and self‑cleaning teeth eliminate clogging, improve availability, and reduce operating costs – delivering real value where traditional crushers fail.

Ready to Solve Your Clogging Problems?

Contact Huashengming today. Send us your material sample and moisture data – our engineers will recommend the right model and tooth profile for your application.

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