Looking for a Two-Stage Hammer Crusher to Boost Your Crushing Plant Efficiency?

Two Rotor Hammer Crusher Manufacturers

What is a two-Rotor Hammer Crusher?

A two-rotor hammer crusher, as the name suggests, is a high-efficiency crushing device with two sets of rotors installed in parallel within the same machine body. Each set of rotors is equipped with multiple rows of heavy-duty hammers. The two rotors rotate in opposite directions or in the same direction, forming two continuous crushing chambers. After the material enters the machine, it is crushed by the high-speed impact, collision, and grinding of the two stages of rotors, and finally discharged through the grate screen at the bottom, achieving efficient, multi-stage crushing of the material.

Core Structure and Working Principle Analysis

Unique two-Rotor Design

This is its core advantage. The two rotors are driven independently, and their speed can be optimized and adjusted according to the material characteristics. The first-stage rotor typically performs coarse crushing, initially breaking up large pieces of material; the second-stage rotor is responsible for fine crushing, ensuring uniform and fine particle size of the output. This design is equivalent to combining two hammer crushers into one, but with a smaller footprint and a more compact process.

High-Efficiency Crushing Process

The material first enters the first crushing chamber, where it is violently impacted by the first set of high-speed rotating hammers and thrown against the impact plate on the machine body, resulting in impact crushing. Subsequently, the insufficiently crushed material falls into the second crushing chamber, where it receives more concentrated and higher-frequency impacts from the second set of rotor hammers until the particle size meets the requirements and is discharged through the gaps in the screen plate.

Significant Advantages of the Dual-Rotor Hammer Crusher

1. Extremely High Crushing Ratio and Processing Capacity: The dual-stage continuous crushing results in a very high single-machine crushing ratio, reaching up to 40-50, capable of directly crushing large materials to medium or smaller particle sizes in a single pass, significantly simplifying the process flow and increasing processing capacity by 30%-50% compared to single-rotor equipment of the same specifications.

2. Excellent Finished Particle Size and Shape: After two impact crushing processes, the finished material has a more uniform particle size, less needle-like and flaky content, and a good cubic shape, making it particularly suitable as a pretreatment device before sand making or for the production of high-quality aggregates.

3. Stable operation and minimal over-crushing: By adjusting the two-stage rotor speed and screen gap, the output particle size can be precisely controlled, avoiding over-crushing, reducing energy consumption and powder yield, and lowering operating costs.

4. Strong overload resistance and wide applicability: It has strong adaptability to material moisture content. When processing sticky and wet materials, clogging can be effectively reduced by adjusting the screen structure. Its robust structural design can withstand the instantaneous impact of uncrushable objects (such as iron blocks), protecting the main components.

Successful Application Case

We provided two PCZ-1820 heavy-duty double-rotor hammer crushers to a large building materials group in East China for their 800-ton-per-hour limestone crushing production line. This equipment directly crushes raw materials with a particle size ≤800mm to aggregates ≤25mm in a single pass, simplifying the original two-stage process of "jaw crusher + impact crusher". The equipment has been operating stably for over 3 years, with an average output particle size consistently below 20mm and a needle-like/flaky content below 8%, significantly reducing investment and operating costs for customers and improving overall line efficiency.

Recommended Related Equipment

To build an efficient production line, a dual-rotor hammer crusher is often used as the core intermediate crushing equipment. We recommend the following supporting solutions:

• Upstream Feeding: Heavy-duty plate feeder to ensure uniform and stable feeding.

• Front-end Coarse Crushing (Optional): If the raw material particle size is extremely large (>1 meter), a jaw crusher can be configured for primary crushing.

• Back-end Shaping: If extremely high particle shape requirements are needed, a vertical shaft impact crusher (sand making machine) can be connected for shaping and sand making.

• End-end Screening: Circular vibrating screen for finished product classification; oversized particles can be returned to form a closed-loop cycle.

Frequently Asked Questions (FAQ)

1: What materials are best suited for crushing with a dual-rotor hammer crusher?

It is particularly suitable for medium-hard and less abrasive materials, such as limestone, bluestone, coal gangue, gypsum, and shale. For high-hardness materials (such as granite and river pebbles), hammer wear will be accelerated, requiring a comprehensive assessment of operating costs.

2: What is the biggest difference between it and a single-rotor hammer crusher and an impact crusher?

The biggest difference lies in its two-stage continuous crushing structure. Compared to a single-rotor hammer crusher, it has higher crushing efficiency and crushing ratio; compared to an impact crusher, it is less sensitive to the moisture content of the material, and the wear cost of the hammers is generally lower than that of plate hammers, resulting in better overall benefits for specific material processing.

3: What are the core wear parts of the equipment? What is the replacement cycle?

The core wear parts are the hammers and the screen plate (grate). The replacement cycle depends entirely on the material hardness, abrasiveness, and throughput. Taking limestone crushing as an example, using high-chromium alloy hammers, their lifespan is typically 3000-6000 hours. We offer hammers in a variety of materials and support on-site welding repair services to minimize our customers' costs on wear parts.

Our two-rotor hammer crusher, with its unique design, demonstrates unparalleled advantages in simplifying processes, improving efficiency, and refining particle shape. Choosing a reliable machine is not just choosing a product, but also choosing a partner with 20 years of experience who can provide you with a complete lifecycle solution from selection and design to manufacturing, installation, and maintenance.

About of Baichy Heavy Industry

Baichy Heavy Industry is a high-tech mining equipment company integrating R&D, manufacturing, sales, and after-sales service. Focusing on crushing, grinding, and mineral processing equipment, we provide professional solutions to our customers. We are ISO9001:2015 、certified, and our products include mobile crushing palnts, crawler crushing plant, construction waste crushing plants, jaw crushers, sand making machines, cone crushers, fine crushers, grinding mills, ball mills, etc., all with reliable performance to meet diverse project needs.

Our advantages:

• Professional pre-sales support: Free project design and comprehensive solutions to help you accurately select the right equipment;

• Comprehensive on-site service: Providing installation guidance and worker training to ensure smooth equipment commissioning;

• Reliable after-sales guarantee: A complete after-sales system, timely response to technical inquiries and equipment maintenance, ensuring long-term stable operation.

To protect your rights, please contact us through the following official channels for professional service:

Official Website Customer Service

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We are committed to providing high-quality equipment and full-cycle services to deliver comprehensive intelligent solutions for the global mining industry!