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Roll Crushers are designed to handle the primary, secondary and tertiary stage crushing of friable materials such as coal, salt, clay, bauxite, limestone and other minerals of similar characteristics in the mining, power generation and numerous other industries. Roll Crushers are one of the most widely used crushers in the mining industry and have numerous advantages, such as high capacity, low headroom, low horsepower, the ability to handle wet, sticky feeds and the generation of minimum fines while producing a cubical product.
The simplified design gives these units excellent reliability and requires very little maintenance. Roll Crushers are designed with built-in tramp relief that allows for the passing of uncrushable materials while continuing operation and returning to the initial product setting.
Since patenting the first Single Roll Crusher in 1894, McLanahan has become an expert and leader in the industry in the design and manufacture of single and two stage Roll Crushers. The selection process for each application is based on extensive equipment knowledge and a wealth of test data developed in our research lab or through on-site testing.
McLanahan offers belt-driven Roll Crushers in four designs: Single Roll, Double Roll, Triple Roll and Quad Roll Crushers, which provide a substantial return on investment by operating at low cost and maximizing yield by generating minimal fines. The rugged design, which incorporates a fabricated steel base frame lined with replaceable abrasion-resistant steel liners, stands up to the toughest mineral processing applications while providing safe and simple operation, including an automatic tramp relief system to allow uncrushable objects to pass while the crusher remains in operation. These crushers are also versatile, allowing for adjustments in roll speeds and gap settings to meet most any application requirement.
Whether the application requires a single-stage or two-stage crusher, the forces necessary to perform the crushing remain the same: a combination of impact, shear and compression. The impact force occurs as the material enters the crusher and is impacted by the rotating roll. Shear and compression forces occur as the feed material is pulled between the crushing plate and/or crushing rolls.
Depending on the feed size, material is fed into the crushing chamber and encounters a single or a pair of rotating rolls. If a two-stage reduction is required, either a Triple or Quad Roll configuration can be used. In this scenario, the top stage of the crusher performs the primary reduction either by crushing the material between the roll and crushing plate or between a pair of rolls. The material is then fed directly between the two bottom-stage rolls for additional processing.
If a single-stage reduction is required, then depending on the feed-to-product-size ratio of reduction, either a Single or Double Roll Crusher can be selected. Regardless of the crusher type selected, Roll Crushers allow for the material to fracture along naturally occurring cleavage lines, which helps with minimizing fines generation.
Yes, it will. When a wet, sticky feed is fed to a two-stage crusher, you run the risk of plugging the crusher between the top and bottom stages. If a wet, sticky feed is anticipated and the ratio of reduction requires two stages of crushing, it is recommended that two separate single stages be used.
A good rule of thumb is: Single Roll Crushers have a 6:1 ratio of reduction, Double Roll Crushers have a 4:1, Triple Roll Crushers have a 6:1 on the top stage and a 4:1 on the bottom stage, and Quad Roll Crushers have a 4:1 on both the top and bottom stage.
Single Roll Crushers are typically used as primary crushers that provide a crushing ratio of up to 6:1. They crush materials such as ROM coal, mine refuse, shale, slate, gypsum, bauxite, salt, soft shale, etc., while producing minimal fines. Designed with intermeshing roll teeth and a curved crushing plate, they are extremely effective in reducing slabby feeds.
Double Roll Crushers provide a 4:1 reduction ratio. They are typically used as a secondary or tertiary crusher for materials such as ROM coal with refuse, limestone, gypsum, trona, shale, bauxite, oil shale, clean coal, coke, salt, quicklime, burnt lime, glass, kaolin, brick, shale and wet, sticky feeds. Each machine is custom engineered with roll elements and tooth patterns selected depending on theapplication requirements to produce a cubical product with minimal fines.
Triple Roll Crushers are ideal for producers who want to accomplish two stages of reduction in one pass. They can be used in coal, salt, coke, glass, and trona operations, among others. Triple Roll Crushers combine a Single Roll Crusher with a Double Roll Crusher to form a crusher that is capable of achieving a 6:1 reduction ratio in the primary stage and a 4:1 reduction in the secondary stage while producing a cubicle product at high capacity.
Quad Roll Crushers are ideal for producers, including those with preparation plants, who want to accomplish two stages of reduction in one pass. They can be used in coal, salt, lime, pet coke and potash operations, among others. Quad Roll Crushers are capable of achieving a 4:1 reduction ratio before feeding the crushed material to the secondary stage for an additional 4:1 reduction to make the final product.
The Single Roll Crusher, with its 6:1 ratio of reduction, is ideal for reducing large feed lumps to a medium product size while producing a considerably lower percentage of fines. The minimum product sizing of a Single Roll Crusher is generally limited to 2-3. The crushing is carried out between the full width of the extra-long curved crushing plate and the low-speed crushing roll. The curvature of the crushing plate provides an ample throat opening to capture large irregular feed lumps. The replaceable crushing plate tips or liners are slotted to intermesh with the roll teeth to produce a cubical product and effectively reduce slabbing.
Single Roll Crushers are V-belt driven and employ a large diameter flywheel with a gear and pinion set to reduce roll speed. With the assistance of the inertia generated by the flywheel, this crusher is operated with relatively low horsepower and requires lower headroom in comparison to other crushers used for primary reduction. The roll diameter and width of the crusher will ultimately be dictated by the feed size, product size and capacity.
Single Roll Crushers employ a tramp relief mechanism to allow momentary movement of the crushing plate so the uncrushable object can pass. The mechanism then allows the crusher to return to its original setting and remain in operation.
The Single Roll Crusher, which was originally patented by Samuel Calvin McLanahan in 1894, has evolved over the years to include design features to ensure many years of rugged operation. Complete with all safety guards, the Single Roll Crusher features an automatic tramp relief mechanism that allows the crushing plate to hinge open, pass non-crushable tramp material and return to the previous setting for continued operation.
Based on the application data and extensive field experience, McLanahan selects the proper duty class of Single Roll Crusher for each project. A fully-equipped application research laboratory allows for crushing tests to make sure McLanahan can provide the best possible solution.
A Single Roll Crusher is made up of a toothed roll assembly, which crushes the incoming feed material against a crushing plate. The Single Roll Crusher is designed to reduce larger feed sizes to the desired product size at a 6:1 ratio of reduction while producing a considerably lower percentage of fines. When properly fed in the direction of the roll rotation, the crushing action is carried out along the full width of the curved crushing plate, which ensures maximum throughput capacity. A properly sized roll diameter and tooth configuration grabs the incoming feed and pulls it into the crushing zone without hesitation. The crushing plate has reversible and easily replaceable crushing plate tips, which are designed to produce a cubical product while providing the producer with twice the wear life and simplified maintenance. Single Roll Crushers often require less horsepower and lower headroom in comparison to other crushers used in primary and secondary applications.
These units are designed to make crushing simpler and more effective. McLanahan Single Roll Crushers also feature hydraulic product size adjustment to perform relatively simple changes to the crusher setting if required.
When an uncrushable object, such as metal, roof bolts/timbers, etc., enters the crusher and the force necessary to crush this material is greater than the crushing forces of the crusher, the crusher allows the crushing plate to open and pass the tramp material. The crusher then returns to its previous setting and remains in operation.
Cobra Single Roll Crushers are the lightest duty in the McLanahan line of Single Roll Crushers. They are ideal for wet, sticky feeds and for processing materials such as clean coal, petroleum coke, sulfur, rosin, foundry cores, frozen agglomerates and other friable materials.
Rockmaster Single Roll Crushers are the heaviest-duty model in the McLanahan line of Single Roll Crushers. They are ideal for the most severe crushing applications and reduce extremely hard material and typical mine refuse.
Typically designed for primary crushing, McLanahan Single Roll Crushers efficiently crush material at a 6:1 crushing ratio. . They can continually withstand heavy-impact applications. Single Roll Crushers reduce large size particles in the feed to a medium size, while producing a low percentage of fines.