ROLL CRUSHERS

ROLL CRUSHERS

Roll Crusher consists of two smooth heavy horizontal cylinders

revolving towards each other and the feed material is nipped between
the rolls and pulled downward through the rolls by friction. The
distinguished feature of a roll crusher is that the material is crushed
one time only whilst it is passing through the crushing
chamber.

Due to this fact, the reduction ratio of a roll crusher varies from 3
- 4, the lowest among all the crushers. Production of fines is
minimum.

They can handle friable, dry, wet, sticky, frozen, and less
abrasive feeds well.
 Light and Heavy duty crushers

Roll crushers are arbitrarily divided into two categories

The diameters of the light duty crushers vary between 228

mm and 760 mm with face lengths between 250 mm
and 460 mm. The spring pressure for light duty rolls varies
between 1. 1 kg/m and 5.6 kg/m.

The heavy duty crusher diameters range between 900 mm

and 1000 mm with face length between 300 mm to 610
mm. In general the spring pressures of the heavy duty
rolls ranges between 7 kg/m to 60 kg/m.

The light duty rolls are designed to operate at faster speeds

compared to heavy duty rolls that are designed to operate at
lower speeds.
Parameters of Roll crushers

1. Operating pressure

2. Nip angle

3. Gap

4. Roll speed and

5. Ore size.
 Roll Crushers
For a particular operation where the ore size is known, it is necessary to
estimate the diameter of rolls required for a specific degree of size reduction.

F sinθ = Fμ cosθ

μ = sinθ/cosθ

 The horizontal components of the forces are not responsible in dragging

the particle into the roll gap. It is only the vertical components of the forces
are responsible for dragging the particles into the roll gap for crushing.

 Hence the limiting condition of crushing is that, the sum of the vertical
components of all the forces at the contact point between the ore and roll.
 To estimate μ consider a compressive force, F, exerted by the rolls on
the particle just prior to crushing, operating normal to the roll
surface, at the point of contact, and the frictional force between the
roll and particle acting along a tangent to the roll surface at the point
of contact.

 The frictional force is a function of the compressive force F and is

given by the expression, Fμ.

 If we consider the vertical components of these forces, and neglect

the force due to gravity, then it can be seen that at the point of
contact for the particle to be just nipped by the rolls, the equilibrium
conditions apply where:

F sinθ= Fμ cosθ or μ= tan θ or θ =tan-1μ

It should also be noted that the value of the Coefficient of friction
decreases with speed, so that the speed of the rolls depends on
the angle of nip, and the type material being crushed.
Smooth-surfaced roll crushers are generally used
for fine crushing whereas corrugated or toothed roll
crushers are used for coarse crushing of soft
materials.
(a) Single toothed roll crusher and
(b) Double toothed roll crusher are the two types of
toothed roll crushers used for crushing coal.
 Characteristics of Roll Crushers

1. It has a reduction ratio (r.r) is around 3 - 4 only which is very low compared
to other size reduction equipments.

2. It yields a uniform sized product.

3. The product of the crushing rolls contains fewer fines as the mastification
time is limited and no repeated crushing takes place.

4. Rolls can be operated either wet or dry. Dry crushing has a lower output but
causes lesser wear of the rolls.

5. It is best operated on choke feeding for maximum output. In open feeding the
output is less.
 Capacity of High Energy Roll Crushers

Under continuous and steady feeding conditions the capacity is given by:

Q = 188.5 D W ω L ρB tons/hour

where D = diameter of roll, m,

W = width of roll, m,
ω = speed, rpm,
L = set or distance between rolls, m,
ρB = bulk specific gravity of the mineral, t/m3

The actual capacity is considerably less and is only around 10 - 30% of the
theoretical capacity. If the set(S) is nil the capacity of the rolls is also nil.
 Power Consumption of Roll Crushers

Within the same reduction ratio the power consumption of roll

crushers vary widely.

The power required could be expressed by the general

equation:

P = Capacity x Reduction Ratio x work index

In industry the low pressure smooth surfaced rolls are

designed to draw 8 - 50 kW of power under dry conditions.
The heavy duty rolls draw between 40 and 550 kW depending
on size and low moisture conditions.
 Uses Roll Crushers

 The rolls are most suitable in effecting only a smaller size

reduction in a single operation.

 Therefore, it is common to employ a number of pair of rolls

in series to achieve higher reduction ration.

 Crushing rolls are extensively used in crushing oil seeds,

gun powder and coal because of lower residence time of
the feed as lower residence time reduces the effect of heat
on the feed material.
 Fine Crushers
Impact crushers.
Coarse particle to fine, even to
200 mesh
 Hammer mill
Hammer mill is one type of impact crusher.

Impact crushers reduce the particles by impact forces applied

through sharp blows of fixed or free swinging hammers
revolving about central rotor at high speed to the free
falling particles against stationary surfaces.

These mills are used for relatively soft, friable, and sticky ores
such as phosphates, limestone, clay, graphite and coal.
Special Crushers

Bradford Breaker
 Bradford Breaker

Bradford breakers are used at mines around the world to crush, size and clean run-
of-mine coal and other friable materials