ROLL

CRUSHERS
SIZE REDUCTION
SIZE REDUCTION INVOLVES REDUCING THE SIZE OF PARTICLES SO AS
TO GET MORE PRODUCTS.
LAWS INVOLVED IN SIZE REDUCTION ARE : RITTENEGERS LAW ,KICKS
LAW AND BONDS LAW .
FORCES INVOLVED IN SIZE REDUCTION ARE IMPACT, COMPRESSION,
ATTRITION AND SHEARING.
 TYPES OF CRUSHERS
Crushers are classified according to the stage of crushing which they
accomplish, such as: Primary,Secondary,Tertiary
A primary crusher receives the stone directly from a quarry after
blasting, and produces the first reduction in size.
The output of the primary crusher is fed to a secondary crusher, which
further reduces the stone size. Some of the stone may pass through
four or more crushers before it is reduced to the desired size.
The degree of breakage is spread over several stages as a means of
closely controlling product size and limiting waste material.
As stone passes through a crusher, the reduction in size may be
expressed as reduction ratio.
The reduction ratio is the ratio of crusher feed size to product size.
 ROLL CRUSHER
Roll crushers are used for producing additional reductions in the sizes of stone after the
output of a quarry has been subjected to one or more stages of prior crushing.
Roll crushers have a theoretical MAXIMUM reduction ratio of 4:1. If a 2 inch particle is fed
to the roll crusher the absolute smallest size one could expect from the crusher is 1/2
inch. Roll crushers will only crush material down to a minimum particle size of about 10
Mesh (2 mm). A roll crusher crushes using compression, with two rolls rotating about a
shaft, towards the gap between the rolls
 The particles are drawn into the gap between the rolls by their rotating motion and a
friction angle formed between the rolls and the particle, called the nip angle.
The two rolls force the particle between their rotating surface into the ever smaller
gap area, and it fractures from the compressive forces presented by the rotating
rolls.
Some major advantages of roll crushers are they give a very fine product size
distribution and they produce very little dust or fines.
Rolls crushers are effectively used in minerals crushing where the ores are not too
abrasive and they are also used in smaller scale production mining of more abrasive
metal ores, such as gold.
Coal is probably the largest user of roll crushers, currently, though. Coal plants will
use roll crushers, either single roll or double roll, as primary crushers, reducing the
ROM coal.
ROLL CRUSHER CIRCUIT
DIAGRAM
SINGLE ROLL CRUSHERS
DOUBLE ROLL CRUSHER
Working Principle and Structure of Double Roller Crusher
1.this series of roll crusher is mainly formed by the roller, roller support bearing,
compression and adjusting device, drive components etc.
2.the adjustment of the particle size: between the two rollers equipped with adjustment
device like pads or wedge.The wedge-shaped device has a adjusting bolt on top, when
the adjustment bolt pull up the wedge, the wedge will push the
movable roller away from the fixed roller,then the gap
between two rollers is larger and produce larger particle
size. When the wedge falls down, with the effect of the
compression springs, the movable roller makes the gap
become smaller between two rollers and thus produce
the smaller particle size. Pad device can adjust the output
size by changing the quantity of the pads or its thickness,
Adding more pads,larger gap between two rollers, and
when reducing the pads,it comes the smaller gap and
smaller output size.
3.drive device is composed of two electric motors.V-belt drags the rollers
through drive of the grooved pulley, move and rotate in the relative
direction. In the crushing, the materials enter the feed opening and
through the rollers, rolled and grinded, the finished products will discharge
from under the chassis.
4.for safety, drive part should install the security cover according to the
actual situation respectively.
Application of Double Roller Crusher
The double roll crusher is applied in the industry of cement, chemical,
electric power, metallurgy, building materials, refractories and other
sectors for crushing medium hard materials such as medium and fine
crushing of limestone, slag, coke, coal and other materials.It is more
superior than ordinary crushers especially in the construction Materials
Industry like pisolite and greenbean shake production
SMOOTH ROLL
CRUSHERS
TOOTHED ROLL CRUSHER
CONTAIN 1 OR 2 CURVED ROLL WORKING AGAINST A STATIONARY
CURVED BEAKER PLATE
THEY ARE MORE VERSATILE THAN SMOOTH ROLL CRUSHER BUT CANNOT
HANDLE VERY HARD SOLIDS
THEY OPERATE BY COMPRESSION,IMPACT AND SHEAR AND SO IT CAN
REDUCE MUCH LARGER PARTICLES
SUITABLE FOR FRIABLE AND BRITTLE MATERIALS LIKE COAL, SOFT
LIMESTONE, SLAG,CLAY ETC
CAPACITY OF ROLL
CRUSHER
The capacity of a roll crusher will vary with:
The kind of stone
The size of feed
The size of the finished product
The width of rolls
The speed at which the rolls rotate
The extent to which the stone is fed uniformly into the crusher.
POWER CONSUMPTION OF ROLL
CRUSHERS
WITHIN THE SAME REDUCTION RATIO POWER CONSUMPTION OF ROLL CRUSHER VARY
WIDELY

THE POWER REQUIRED COULD BE GIVEN BY GENERAL EQUATION :

ANGLE OF NIP
PROBLEM
QUESTION
IF CRUSHING ROLLS, 1M IN DIAMETER ,ARE SET SO THAT THE
CRUSHING SURFACES ARE 12.5mm APART AND THE ANGLE OF
NIP IS 31.WHAT IS THE MAXIMUM SIZE OF PARTICLES THAT
SHOULD BE FED TO THE ROLLS ?
ANSWER
THE PARTICLE SIZE MAY BE OBTAINED FROM :
cos =(r1+b)/(r2+b)
In this case, 2 = 31
cos = 0.964
b = 12.5/2 =6.25 mm = 0.00625 m
r1 = = 0.5 m

0.964 = (0.5 + 0.00625)/(0.5+r2)

r2 = 0.025 m = 25mm
THANK YOU