new gangue toothed roll crusher in south america

toothed roll crusher|teeth roller crusher-stone crushing machine - henan fote machinery co., ltd

Toothed roll crusher is a new product independently researched and developed by our company and it is suitable for crushing the raw coal including gangue in large-sized coal mines and coal dressing plants in coal, metallurgy, mine, chemistry and building material industry. Toothed roll crusher has big crushing capacity, the electromotor and the reducer are connected with torque-limiting hydraulic coupler to avoid dynamic overload and the sensor adopts overload protection, so that it is safe and reliable.

The space between the pin rolls adopts hydraulic adjustment and the bearings of the pin rolls uses central lubrication. The tooth from adopts optimized design and the pulling and cutting force can conduct selective crushing with high efficiency, low energy consumption and even discharging. Toothed roll crusher has the advantages of small size, big crushing ratio, low noise, simple structure and convenient maintenance and the features of high productivity, even granularity of the crushed materials, low over-crushing rate, flexible overload protection and safety and reliability.

This toothed roll crusher is mainly composed of transmission device, frame, crushing roll, mechanical spring device and link gear. It mainly relies on the high-speed revolution of the unique wear-resisting rolls to split and crush the materials, thus forming high-productivity mechanism.

Model Roller diameter mm Roller length mm Max. Feeding Size mm Discharging sizemm Output t/h Motor power (kw) Total weight(t) Overall dimension LWH mm 2PGC600500 600 500 200-450 15-100 30-60 4P 112 3.8 24501800950 2PGC600800 600 750 300-600 20-120 60-100 4P 18.52 7.2 450019001350 2PGC8001000 800 1000 500-800 30-150 100-160 4P 222 12.6 255020501100 2PGC10001000 1000 1000 700-950 30-200 150-200 6P 452 18.8 278041001550 2PGC12001200 1200 1200 800-1050 30-200 180-250 6P 552 29.5 278032001980 2PGC15001200 1500 1200 1000-1150 30-200 200-300 6P 752 38.6 801045002050

Toothed roll crusher is a new product independently researched and developed by our company and it is suitable for crushing the raw coal including gangue in large-sized coal mines and coal dressing plants in coal, metallurgy, mine, chemistry and building material industry. Toothed roll crusher has big crushing capacity, the electromotor and the reducer are connected with torque-limiting hydraulic coupler to avoid dynamic overload and the sensor adopts overload protection, so that it is safe and reliable.

The space between the pin rolls adopts hydraulic adjustment and the bearings of the pin rolls uses central lubrication. The tooth from adopts optimized design and the pulling and cutting force can conduct selective crushing with high efficiency, low energy consumption and even discharging. Toothed roll crusher has the advantages of small size, big crushing ratio, low noise, simple structure and convenient maintenance and the features of high productivity, even granularity of the crushed materials, low over-crushing rate, flexible overload protection and safety and reliability.

This toothed roll crusher is mainly composed of transmission device, frame, crushing roll, mechanical spring device and link gear. It mainly relies on the high-speed revolution of the unique wear-resisting rolls to split and crush the materials, thus forming high-productivity mechanism.

Model Max. Feeding Size mm Discharging sizemm Output t/h 2PGC600500 200-450 15-100 30-60 2PGC600800 300-600 20-120 60-100 2PGC8001000 500-800 30-150 100-160 2PGC10001000 700-950 30-200 150-200 2PGC12001200 800-1050 30-200 180-250 2PGC15001200 1000-1150 30-200 200-300

coal crushing: new-type toothed roll crusher vs traditional toothed roll crusher | hxjq

In the coal industry, the requirements for the particle size of the finished product are extremely strict. Generally, the particle sizes of the finished products are between 25 and 70 mm. If it is too large, the furnace will be blocked and further coal processing can't be performed.

Toothed roll crusher is the mature coal crushing equipment applied in the current coal industry, which satisfies all the demands of customers by its advantages of large capacity and low over-crushing rate.

Based on the original toothed roll crushers, HXJQ Mining Machinery has optimized the structure and materials of rollers according to the customers' requirements, so that to adapt the nature of hard gangue and special working conditions and ensure the normal production of coal enterprises.

Traditional toothed roll crusher is usually driven by double-motors. Two sets of motors, couplers and reducers are adopted to drive the independent rollers so that the rollers have the power to crush large coal materials.

The coupler is applied between reducer and rolls to transfer torque. And the toothed rollers and drive system are connected with the machine frame respectively to eliminate the vibrating of toothed roll crusher.

Traditional toothed roll crusher with ring structure has the advantages of stable and reliable performance, and the disadvantages of low wear resistance and hard to replace. Once the traditional toothed roll crusher is damaged, it must be returned to the factory for overhaul.

The traditional rollers are connected by the bolts and tooth-holders, which offers small bearing capacity. Therefore, the traditional toothed roll crushers are mainly applied in the clean-coal crushing process, because the raw coal will cause damage to roll crusher teeth.

In terms of tooth position, the roll crusher teeth are set in the peripheral direction, adopting the setting form of large tooth alternating with a small one. Under the premise of normal discharging size, the crushing force of roller can be improved efficiently, so that to increase the capacity, wear-resistance and service life.

As the picture shows, the new-type tooth-holder adopts the form of regular octagon. The toothed rollers and toothed holders are connected by the flat kay and socket head cap screws (the traditional ones are connected by bolts).

The contacted areas between tooth and toothed holders are processed and improved completely, and torque is transferred by flat key so that can prevent the socket head cap screws from the shearing force of coal materials. And the screws can be firmer and more reliable.

Meanwhile, the fastening bolt and the toothed roller holder are connected by the screw fastening blocks, which makes that the joint strength is ensured, and the interchangeability and the replaceability are also reliable.

The teeth are the main wearing parts of the toothed roll crusher, so it is very necessary to choose a suitable material. Therefore, it is required that the material should have enough hardness, toughness, impact resistance and wear resistance. Also, the following machinability and weldability should be considered.

When parts of high manganese steel are impacted repeatedly, the surface of parts gets changed, and the hardness increases rapidly, which can reach up to HRC54. It will improve the wear resistance significantly, but the inside of parts keeps flexibly. These are the main features of high manganese steel.

However, the toothed roll crushers crush coal materials by shearing and stretching, along with less impacting and squeezing, which makes high manganese steel can't play its advantages to enhance the hardness and strength. Therefore, high manganese steel is not suitable for making teeth.

To better improve the wear-resisting performance of teeth, traditional toothed roll crusher always adopts the low-alloy quenched and tempered steel as the material to make tooth of roll crushers. In general, 40 Cr is used to process the tooth. After processing, the compressive strength and the service life of tooth are improved.

However, since there are only a few millimeters thick wear-resisting layer in the surface of the tooth, it is required to be overlaid frequently in the process of use, which brings a large workload to workers.

The teeth of the new toothed roll crusher adopt the integral casting molding process, optimizes the proportion of the main elements such as C, Cr, Mn, Mo, Si, Ni. The medium carbon bainitic steel is selected finally to be the material of toothed roll.

The medium carbon bainitic steel has good hardenability. After quenching and tempering heat treatment, bainite with high hardness and wear resistance is processed. It has an excellent comprehensive performance of HRC50 hardness and compressive strength of 1500 MPa.

In addition, the material of the entire toothed roller structure, including the toothed roller, the toothed roller holder and the threaded fastening block, is reasonably matched, so that the strength and hardness of each component are more balanced and reasonable.

The raw coal is first crushed to below 300mm by the jaw crusher, and then crushed to below 70mm by a toothed roller crusher, and then transported to the coal storage bin by the belt conveyor. After screening, the final product of 25~70mm is sold to the chemical company.

The customer said it requires technical improvement urgently in their worksite urgently to reduce the operating cost of the enterprise and the labor intensity of the workers and to ensure the normal operation of the production system.

Since the new toothed roller crusher was put into use, the equipment has been running stably, the discharge size of the products is significantly improved, the over-crushing rate reduces, and the block-forming rate is highly increased (see the following table).

It can be seen from the above table that the difference between the qualified products before and after the replacement is 18.2%, which greatly improves the output of qualified products and creates great economic benefits for the enterprise.

In addition, the new toothed roller crusher has high wear resistance, and the fastening bolt is not easy to loosen, which reduces a large amount of maintenance time, the labor intensity of workers, and the maintenance cost of the coal crushing process.

With the transformation and upgrading of the coal industry, it is an inevitable trend to vigorously develop coal chemical industry. The coal chemical industry has strict requirements on the particle size of coal, which puts higher requirements on the crushing equipment.

The new toothed roller crusher can optimize the crushing operation of the raw coal by a series of optimizations on the structure and material of the toothed roller. It has a high block rate and a small maintenance amount. With the obvious technical advantages, the promotion prospects of new-type toothed roll crusher are broad.