June 22, 2020

University of Engineering and Technology, Peshawar

(UETP)

Department of Mining Engineering

(ME)

LAB REPORT– 03
Course Title: Mineral Processing I Lab
Report Name: Measurement of Reduction Ratio of Roll Crusher

Submitted To:
Engr. Sajjad Hussain
Dept. of Mining Engineering
Submitted By:
Bilal Ahmad
6th Semester
Reg. No. 17PWMIN0806
Dept. of Mining Engineering

Date of Submission: June 23, 2020

1
 June 22, 2020

Experiment # 03: Reduction Ratio of Roll Crusher

Objectives:
1) To get familiar with various parts and functions of roll crusher.
2) To get to know about how to perform crushing test on a rock sample.
3) Analyzation of product with the help of sieve analysis.

Apparatus:
 Lab roll crusher
 Rock samples
 Sieve shaker
 Sieve set (9.42, 6.70, 4.75, 2.36, 0.85 and 0.30mm)

Theory:
A type of secondary or reduction crusher consisting of a heavy frame on which two rolls are
mounted. These are driven so that they rotate toward one another. Rock fed in from above is nipped
between the moving rolls, crushed, and discharged at the bottom. There are various different types
of roll crusher which are given below

1) Single roll crusher

2) Double roll crusher
3) Triple roll crusher
4) Quad roll crusher

Single Roll Crusher:

A simple type of crusher for coal, with a drum to which are bolted toothed segments designed to
grip the coal, forcing it down into the crushing opening. Single roll crusher carries out size
reduction in a wedge-shaped crushing area by pressure and shearing stress. The crushing body is
composed of a rotating roll and adjustable and spring mounted crushing plate located on opposite
side. The distance between the base of crushing plate and tips of the roll crusher teeth determine
the adjustable gap width, which can be varied depending on desired product size. It is a primary
crusher with a reduction ratio of upto 6:1.

2
 June 22, 2020

Figure 1: Single roll crusher

Double Roll Crusher:

Dual roll crusher is a type of either secondary roll crusher or tertiary roll crusher with a reduction
ratio upto 4:1. Roll crusher is a compression type crusher. It consist of two rotating drums moving
towards each other. The material which is to be crusher is crushed into pieces when it comes in
between two rolls. Dual roll crushers are either dual smooth roll crusher or dual teeth roll crusher.

Figure 2: Dual Roll Crusher

Triple Roll Crusher:

Triple roll crusher consist of three rolls which provides a reduction ratio of 6:1 in the primary stage
and then provide reduction ratio of 4:1 in secondary stage. This type of roll crusher is mainly used
for crushing coal, salt, coke and glass. The choice of selecting triple roll crusher depends on the
producers who want to complete greater reduction ratio in one pass.

3
 June 22, 2020

Figure 3: Triple roll crusher

Quad Roll Crusher:

Quad roll crusher consist of four rolls accomplishing two stages of reduction in one pass. Quad
roll crusher achieve 4:1 reduction ratio at both the primary and secondary stage. This simplified
process does not require timing gears. Quad roll crusher can greatly improve production and
efficiency for material processing all while remaining safe and easy to maintain.

Figure 4: Quad roll crusher

Working Mechanism of Dual Roll Crusher:

The feed which is to be crushed is drawn into the feed chamber. Due to the inward rotating motion
towards each other of both the roller, the feed material is forced to go through these two rollers
and ultimately material is crushed due to the compressive forces produced by the rollers. The
crusher material is collected from the bottom.

4
 June 22, 2020

Related Terminologies:

Angle of Nip:
The particles are drawn into the gap between the rolls by rotating motion and the friction angle
formed between the rolls and the particle, called angle of nip.

Reduction Ratio:
It is the ratio of size of feed to the size of output.

Procedure:
1) First of all, turned on the machine switch and observe the motion of the rolls whether they
are moving towards each other or away from each other.
2) Now adjust the set to 10mm by measuring distance between the rolls at the line joining
their centers.
3) Now measure the maximum linear length of particle among the sample before putting the
sample into the crusher.
4) Feed the sample to be crushed into the crusher.
5) Once it is crushed, again measure the maximum linear length of particle.
6) Perform sieve analysis on the product.
7) Once it is done, measure the reduction ratio of the machine or crusher.

Observation and Calculation:

Sample to be crushed: Rock

Weight of sample: 2kg

Maximum linear length of feed sample: 7cm

Maximum linear length of feed sample: 2cm

Reduction Ratio: 3.5 : 1

5
 June 22, 2020

Results and Discussion:

After calculation and observation, we have obtained that reduction ratio of dual roll crusher is
3.5 : 1. The sample to be tested is an ore.

Conclusion:
Hence we have successfully determined the reduction ratio of machine and performed the crushing
test on a sample. Further we are familiar with the various parts and the working mechanism of dual
roll crusher.