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Williams is an industry-leading roll crusher manufacturer and designer for high-quality roll crushers with desirable benefits such as high throughput capacity, minimal maintenance requirements, low cost per ton operation, and more. Learn more about our heavy-duty roll crushers below or contact our sales engineers to talk about your application needs.
A combination of impact, shear, and compression are the forces necessary to perform the crushing and size reduction in a Williams roll crusher. The material enters the roll crusher machine and is impacted by the roll as it rotates. Then, as the material is pulled between a crushing plate or rolls, shear and compression forces act upon the material. The rolls act as flywheels, contributing to smooth operation and efficient use of power. Roll crushing surfaces operate at a fixed distance apart, as opposed to the continually changing distances in a jaw or cone crusher. This creates a more consistent product size.Roll crushers are low in profile and relatively easy to install. They can be fed with a minimum of headroom, or even choke fed. Adjustments are simple andinternal parts are readily accessible.
Typical feed materials for Williams Roll Crushers include: bauxite, cement clinker, chalk, cinders, clay, coal, glass, gypsum, limestone, burnt lime, rock salt, sandstone, shale, sulfur ore, sea shells, and sewer sludge clinker. Single Roll Crushers, sometimes called lump breakers, can also be used for breaking frozen or agglomerated materials.
Williams Roll Crushers are used in a variety of industries such as, mining recycling, and power industries. Interested in learning more about the Williams Roll Crushers for your specific industry and application? Contact our sales engineers!
Choosing between a single roll crusher and double roll crusher depends upon the type of feed material, feed size, product size desired, and consistency of both feed and product. Both single and double roll crushers operate most efficiently with dry, friable materials. However, single roll machines have been widely and successfully used for the reduction of moist clays. They also have been long used as primary and secondary coal crushers, both at mine sites and power plants, where a minimum of fines is desired.
Williams single roll crushers reduce via a combination of impact, shear, and compression. The rolls are always toothed in patterns suited to the feed material. Single Roll Crushers generally handle larger feed sizes at higher reduction ratios in higher capacities and are particularly well suited to be used as lump breakers.
Double roll crushers reduce primarily through compression, although some shear is obtained with toothed rolls. Rolls for these crushers come in combinations of smooth, corrugated, and toothed designs. Double Roll Crushers produce a finer product at lower reduction ratios and capacities.
Oversized, heat-treated, alloy steel shafts plus self-aligning, roller-type bearings assure long life and maximum use of power. Jackshafts for control of roller speed are standard on double roll crushers, optional on larger Single Roll Crushers.
Heavy-duty compression springs permit movement of floating roll to pass tramp metal and other uncrushables, avoiding overload and damage. Smaller Single Roll Crushers are equipped with a shear pin release.
Faces Tooth patterns and corrugations to fit feed material; abrasion-resistant alloy; easily replaceable. Ash Crushers have additional features including dust-tight design and sealed cover plates for breaker plate access.
Williams Single Roll Crushers are also available in a 15 inch (381mm) diameter dust-tight version for applications such where it would be expensive to have dust collection air. Already well known for rugged construction, low profile, high reduction ratio, and economical cost, Williams Dust-Tight Ash Single Roll Crushers also have easy access to the rotor for maintenance. These dust-tight roll crushers are perfect for applications such as crushing ash, limestone, coal, or glass.
Although its brief period of popularity passed some thirty-odd years since, and only a few sets were installed before interest reverted to other types, the high-speed double roll crusher developed by Thomas A. Edison shortly before the end of the last century warrants a place in any discussion-of crushing equipment. In 1960, the largest machine of this type the 6 x 7 foot giant rolls were huge crushers, judged even by present-day standards; they have an unobstructed receiving opening 7 x 7 foot and their capacity on individual skip-loads of stone is enormous, although, as will be explained, they cannot maintain this peak capacity over a period of time.
Mechanically, the teethed roll crusher is a very simple machine. The two rolls are carried in bearings, supported on two very heavy and rigid bed castings which are secured on the concrete foundation by a number of large anchor bolts. The bearings, in addition to being bolted to these bed castings, are prevented from spreading by pairs of large tie-rods which pass through them above and below the roll shafts. Unlike the smooth-face crushing rolls we have described, these tension rods are not cushioned by springs. The machine is surmounted by a heavy cast rectangular hopper, all sides of which are vertical. Each roll is independently driven by a flat-belt pulley.
The roll-centres are octagonal in cross section, each face being provided with a spline groove and a series of tapped holes for securing the chilled- iron wearing plates. These wearing plates have the sledging knobs, or teeth, cast on their outer surfaces. Thus we have a roll surface that resembles that of the one rollcrusher, except that the faces of all teeth are sloped instead of radial on the advance side. The usual practice is to fit one roll entirely with so-called regular teeth, and the other roll with six rows of regulars and two rows of higher (slugger) teeth.
The peripheral speed, or tip-velocity, of these rolls is much higher than that of any of the machines we have previously described. The range of the smooth-face rolls, for example, is from about 400 ft/min for the small 12-in. rolls, to 2000-2200 feet/minute for the heavy-duty 72 machine. The single-roll crusher has a tip speed of 400-450 ft/min while the 6- x 7-ft teethed roll crusherhas a normal, no-load, surfaces speed of just under 3500 ft/min. It can be readily appreciated that this high velocity induces an extremely violent crushing action, in conjunction with the 3- to 4-in. knobs which protrude from the roll surfaces. Impact, sledging, and pressure crushing enter into the over-all performance; but impact, in this crusher, plays a far more important role than it does in the slower speed single-roll machine; and crushing, even well down along the roll faces, is more in the nature of a sledging action than it is of pressure crushing, for this action occurs in the lower-velocity crushers.
The theoretical maximum size of cube that the knobs will grip, when the rolls are set at minimum spacing, is 24; but the rolls will reduce any stone that can be introduced into the 7-ft square hopper. Large blocks will span across the tops of the two rolls; immediately the slugger teeth on the one roll so equipped go to work on these blocks and quickly shatter them into pieces that can be gripped between the sets of regular teeth; from this point on, the action is a mixture of sledging and pressure crushing. The same selective segregations which we described in connection with the single-roll machine occur in the double-roll crusher; the smaller pieces are cleared quickly, leaving the roils free to work on the larger blocks.
The entire performance on individual skip-loads of stone takes place in a very short period of time. Ten- ton loads of mixed-size medium limestone will clear the crusher in from 10 to 15 sec.; large single blocks, weighing from 6 to 8 tons, are crushed in from 5 to 20 seconds, depending upon the toughness of the individual piece, and upon the way it happens to land in the crushing chamber. These performances were clocked on ma-chines turning out a 6 product.
The short-time transfer of energy, especially when crushing large blocks, is very high; so high in fact that it would not be economically feasible to provide sufficient motive power to deliver it. The usual practice, when these rolls are driven electrically, is to drive the slugger roll with a 250 HP motor, and the regular roll with 200HP,a total of 450 HP. As compared to this motive power, instantaneous energy delivery may run as high as 4000 HP, obviously far beyond the capacity of the motive equipment. But the rolls themselves, when running at normal no-load speed, have a stored kinetic energy of upwards of 4,000,000 ft -lb , and it is this stored energy that does much of the actual crushing, the motors serving to bring the rolls back to normal speed between crushing periods. In crushing a skip-load of stone the rolls may lose anywhere from 30 to 60 RPMin speed; this loss occurs partly through slowing down of the motive equipment, and partly through belt slippage. It requires from 5 to 10 sec. to bring the machine back to speed, during which time the power input will vary from 400 to 600 HP. The power required to run the rolls empty is something less than 100 hp. The average power consumption, when crushing from 3000 to 4000 tons per 10 hour day will run in the neighbourhood of 150 HP on medium limestone.
While the average power consumption of this machine compares favorably with that of other types, the rather violent fluctuation outlined and the relatively high connected horsepower are unfavourable features. It is also natural to expect that the belt slippage we have noted would constitute something of a problem over a period of time. Performance records indicate that belt trouble accounts for about 50% of the total lost time on a set of these rolls, and about 25% of the total maintenance expense.
The type of quarry equipment most commonly used in conjunction with this crusher is the three-sided steel skip, carried on a flat-top truck or flat car. These skips are provided with a shackle on the rear end, which is engaged by a hook actuated by a small hoist. This apparatus slides the skip over against the lip of the receiving hopper, and tilts it to discharge its contents. The skips discharge over a feed-roll which retards the flow of material so that the entire load does not drop into the crushing chamber at once. When the skip is empty it is pulled back on to the truck or car by a counterweight attached to the opposite end of the same cable which performs the hoisting operation.
We have mentioned the heavily ribbed hopper which surmounts the frame and extends up to the level of the feed roll. This hopper serves the double purpose of directing the material into the crushing zone, and preventing stones thrown by the slugger teeth from flying out of the crusher. It is also necessary to cover the top of the hopper with heavy netting to contain flying spalls.The straight-sided, rectangular hopper construction, and the violent agitation in the crushing chamber, tend to minimize blocking and bridging in this crusher. When bridges do occur they are difficult and dangerous to break while the rolls are running.
Practically all that we have had to say about the application of the single-roll crusher will apply as well to the Edison toothed roll crusher. It is better adapted to handling blocky stone than is the single-roll machine, because itsslugging action is much more vigorous, and it will handle any material that will not build up on the sides of the vertical hopper. It is not as simple a machine to feed as the single roll crusher, because its narrow hopper necessitates the uses of skips, or very short-bodied cars. A heavy- duty apron feeder would of course solve this problem, but so far as we know, none of these crushers were so equipped. The high peak capacity of the crusher constitutes something of a problem in plants of medium capacity. It is not economically feasible to provide elevating or conveying equipment to handle peak loads of around 4000 TPH in a plant designed to turn out that much stone in an 8 or 10 hr day; consequently means must be provided to smooth out these high surge loads. This can be taken care of by a surge bin and feeder below the crusher, or by passing the roll product direct to a secondary crusher of uniform-capacity characteristic. A feeder ahead of the rolls would smooth out peaks on mixed feed but. once a 10 or 12 ton block of stone is dropped into the crusher, that quantity comes through very quickly as crushed stone, which would render the regulating properties of the feeder of questionable value.Modified forms of this crusher were used by Edison for secondary and tertiary stages. The crushing equipment in one large plant, for example, comprised a set of 6- x 7-ft rolls (8 product), a set of 4 x 4 feet secondary rolls (3.5 product), and a set of 4 x 3 ft tertiary rolls (1.5 product), these last rolls being in closed circuit. These smaller machines were also run at high speeds, their surface velocities being slightly over 3000 ft/min.
Cutting centre consisting of a BSA horizontal splitting machine with integrated de-stacking device and a vertical OFS-VS contour cutting machine for the automatic cutting of blocks into sheet ware and from sheet ware into contours without any manual intervention
Automatic horizontal cutting machine with reversing belt system and stationary cutting unit for the economic cutting and splitting of sheets into various thicknesses and into lengths of 10 m and upwards.
The Albrecht Bumer GmbH & Co. KG has been a leading manufacturer of machines and equipment for the foam industry for more than 70 years. The company focus is on special machinery and equipment. In this area, we have grown as a medium-sized company from pioneer to world leader.
Ecoman is one of the top most-preferred crusher manufacturing, selling and distribution company, which makes efficient and exclusively customized single roll crushers that best suit the special requirements of varied industrial applications. Alongside the double roll crusher machines that Ecoman manufactures, the single roll crusher machines also add a great value towards enhancing the scope for better production in various industries like \metallurgy, mining, building material and energy. We manufacture and distribute best quality single roll crusher as well as an eminent double roll crushers of two types - double toothed roll crushers and smooth double roll crushers along with sinter crushers. The single toothed roll crusher that we manufacture is actually a rotary roller which consists of a large tooth and also a crushing plate which is adjustable according to the need and requirement. The material that is fed into the single roll crusher is smashed first and then pressed from inside of the single tooth roll breaker followed by passing it through the braking cavity after which the rotary roller shifts it to the space amidst the tooth roller and the crushing plate which break the material into desired shapes. Our single roll crusher has a utility space in industries like ROM coal Mine refuse Shale Slate Gypsum Bauxite Salt Soft shale Cinders Brick Phosphate Clean coal Frozen coal Lime Coke Wet and Sticky feeds Salient features of our single roll crusher Fabricated steel base constructed frame Renewable, high quality steel wear liners based Hopper and frame reinforcement Replaceable, reversible and renewable crushing plates reinforcement Driven by an electric motor and V-belt drive arrangement Automatic lubrication option available
Ecoman is one of the top most-preferred crusher manufacturing, selling and distribution company, which makes efficient and exclusively customized single roll crushers that best suit the special requirements of varied industrial applications. Alongside the double roll crusher machines that Ecoman manufactures, the single roll crusher machines also add a great value towards enhancing the scope for better production in various industries like \metallurgy, mining, building material and energy. We manufacture and distribute best quality single roll crusher as well as an eminent double roll crushers of two types - double toothed roll crushers and smooth double roll crushers along with sinter crushers. The single toothed roll crusher that we manufacture is actually a rotary roller which consists of a large tooth and also a crushing plate which is adjustable according to the need and requirement. The material that is fed into the single roll crusher is smashed first and then pressed from inside of the single tooth roll breaker followed by passing it through the braking cavity after which the rotary roller shifts it to the space amidst the tooth roller and the crushing plate which break the material into desired shapes.
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.
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.
Roll crusher, also known as roller crusher, belongs to traditional crushing equipment. It is mainly used for fine processing of material particles. As the main working part, the two cylindrical rollers rotate oppositely to achieve the purpose of crushing. Due to its peculiar tooth crushing structure, it is also called Teeth Roll Crusher.
The commonly seen roller crusher falls into three types: single roll crusher, double roll crusher and four roll crusher. In the working process, material falls in between the two rollers, and will be crushed. Normally, the material will be discharged from the bottom.
When encountering material with high hardness, the rollers will automatically concede by hydraulic cylinder or spring which will increase the space between the two rollers, resulting in the falling of material with high hardness and uncrushable material, to protect the machine from damage. Changing the space between the two rollers can definitely control the maximum particle size of discharged material.
The double roll crusher can be applied in industrial sectors, such as cement industry, chemical industry and building materials industry for medium and fine crushing of material with medium and high hardness like limestone, coke, coal, etc. Double roll crusher features a two roll structure with smooth surface.
Teeth roll crusher is available in two roll and four roll series. According to the characteristics of material, coarse and fine teeth can be chosen. Four roll type teeth crusher is actually made up of two double roll teeth crushers.
Teeth roll crusher is outstanding for its large crushing capacity. In addition, the hydraulic coupling with limited distance connecting the motor and reducer prevents overload and the overload protection sensor device makes the machine safe and reliable. The hydraulic adjustment of tooth roller space and central lubrication of tooth roll bearing are additional advantages. The optimization design of tooth shape and selective crushing make roll crusher a machine with high efficiency and low energy consumption and uniform granularity.
Bevcon Single Roll Crusher is typically primary crusher. The crushing technique involves the operations like Impact, shear and compression. The material entered in the crushing chamber is struck hard against a rotor consisting of series of teeth mounted on a rotor.
Material is crushed between teeth and a breaker plate consisting of hard liners. Providing a crushing ratio of up to 6:1, Bevcon Single Roll Crushers reduce large size particles in the feed to a medium size, while producing a low percentage of fines. The Single Roll Crusher design is very effective in reducing lumpy material because of the interrupted opening between the roll teeth and the corresponding grooves in the crushing plate liners.