Double-roll crusher
The double-roll crusher is one of the simplest and most efficient pieces of equipment for medium and fine crushing, offering the lowest rate of over-crushing (excessive fines generation). It is widely used for crushing medium-hardness materials such as coal, coke, limestone, and metallurgical slag. Bacihy Heavy Industry offers the 2PG series double-roll crusher with immediate availability; it features a maximum feed size of 100mm, an adjustable discharge size of 2–50mm, and an hourly capacity of 5–120 tons. It supports global voltage standards (380V/400V/440V/60Hz), comes with transparent factory-direct pricing, and has a standard delivery time of 15–30 days.
I. What is a Double-Roll Crusher: Working Principle and Equipment Overview
The double-roll crusher consists of two parallel crushing rolls rotating towards each other. Material enters the gap between the rolls from the top inlet and is crushed to the target size through a combination of compression and shearing forces before being discharged. The gap between the rolls directly determines the output particle size and can be quickly adjusted using shims or a hydraulic system. Compared to jaw crushers or impact crushers, the double-roll crusher's greatest advantage is its low over-crushing rate: the roll surfaces act only on material larger than the roll gap, resulting in uniform particle size and minimal fines. This makes it particularly suitable for industries sensitive to the proportion of fine powder, such as coke, coal briquettes, and glass raw material processing.
II. Key Application Scenarios for Double-Roll Crushers
• Coal Mining and Coking: Medium and fine crushing of raw coal, washed coal, and coke; the low over-crushing rate reduces coke breeze loss and increases the yield of lump coal.
• Cement and Limestone: Secondary crushing of clinker and limestone (5–30mm output), providing a stable feed size for ball mills.
• Metallurgy and Slag: Crushing of blast furnace slag, steel slag, and sinter; high-chromium alloy roll surfaces ensure a long, wear-resistant service life.
• Silica Sand and Glass: Crushing and shaping of glass raw materials and silica sand with strict control over fines generation.
• Chemicals and Fertilizers: Crushing of materials such as caked fertilizers, salt, and gypsum; capable of handling sticky or moist materials without clogging.
• Intermediate Crushing in Mineral Processing Plants: Suitable for the intermediate crushing of non-ferrous metal ores; it can be paired with a jaw crusher to form a two-stage "jaw crusher + double-roll crusher" circuit.
Note: This machine is suitable for materials of medium hardness (Mohs hardness below 6); for hard ores, a cone crusher is recommended.
double-roll crusher price
III. Key Specifications of the 2PG Series Double-Roll Crusher
| Model | Roll Dimensions (mm) | Max. Feed Size (mm) | Discharge Size (mm) | Capacity (t/h) | Motor Power (kW) |
|---|---|---|---|---|---|
| 2PG400×250 | Φ400×250 | 25 | 2-8 | 5-10 | 5.5×2 |
| 2PG610×400 | Φ610×400 | 40 | 5-25 | 10-30 | 15×2 |
| 2PG750×500 | Φ750×500 | 45 | 5-30 | 15-45 | 18.5×2 |
| 2PG900×700 | Φ900×700 | 60 | 5-40 | 25-75 | 22×2 |
| 2PG1200×800 | Φ1200×800 | 80 | 8-50 | 45-120 | 37×2 |
Capacity Conversion Note: The capacities listed above are calibrated based on limestone (density approx. 1.6 t/m³). When crushing coke, apply a conversion factor of 0.45–0.55; when crushing slag, apply a factor of 0.8–0.9 to ensure accurate model selection.
IV. Key Advantages of Bacihy Double-Roll Crushers
• Low Over-crushing, High Yield of Finished Product: The rate of fines (powder) can be controlled to within 15%. Taking coke crushing as an example, the yield of lump coke is 8–12 percentage points higher than that of hammer crusher systems; based on an annual output of 200,000 tons, this results in the recovery of finished product worth hundreds of thousands of yuan annually.
• Wear-resistant roll surfaces and low maintenance costs: The roll shells are cast from high-chromium alloy or feature wear-resistant hardfacing; when processing coal or limestone, the roll surface lifespan reaches 6,000–10,000 hours. Only the roll shells need replacement after wear—eliminating the need to replace the entire roll assembly—thereby reducing the cost of a single replacement by approximately 40%.
• Simple structure and low failure rate: The design eliminates hammers and screen bars, resulting in fewer wear parts; routine maintenance is limited to periodic lubrication and inspection of roll surface wear.
• Dual spring/hydraulic overload protection: The movable roll automatically retracts when encountering unbreakable objects (such as metal chunks), protecting the roll surface and drive system; it automatically resets after the object passes, minimizing the risk of downtime.
• Global voltage compatibility: Motors can be customized for 380V/50Hz, 400V/50Hz, or 440V/60Hz specifications, allowing for immediate operation in markets like South Africa, Brazil, and Mexico without the need for transformers.
V. Real-world Application Cases
Case 1: Coal Preparation Plant in Indonesia (2PG900×700) – The client previously used a hammer crusher for run-of-mine coal, resulting in a fine-powder rate of up to 25% and significant loss of lump coal. After switching to the Bacihy 2PG900×700 double-roll crusher, the yield of 0–40mm lump coal increased to 88%, and electricity consumption per ton dropped from 2.6 kWh to 1.8 kWh. Combined savings on electricity and reduced coal powder loss totaled approximately $60,000 annually, with a payback period of less than eight months.
Case 2: Coke Plant in South Africa (2PG750×500) – To address frequent local power restrictions, the unit utilizes a dual-motor independent drive design, allowing for short-term operation on a single roll. Paired with a customized 400V/50Hz motor, peak power consumption is 30% lower than that of a hammer crusher setup, ensuring continuous production despite power supply fluctuations.
Case Study 3: Saudi Limestone Sand-Making Line (2PG1200×800). This unit operates in a two-stage crushing circuit alongside a jaw crusher and a vibrating screen, providing a stable 0–30mm feed to the sand-making machine. After 8,000 hours of annual operation, the roll surfaces show even wear, and spare parts are readily available; the customer has subsequently purchased a second unit.
VI. Selection Recommendations for Double-Roll Crushers
Analyze material before selecting the model: Feed size, moisture content, and hardness directly determine the machine model and roll surface material; if moisture content exceeds 15%, a scraper device for roll cleaning is required.
Calculate capacity using an effective coefficient: Determine actual requirements based on material density and fines content specifications; when selecting, it is better to choose a larger capacity than a smaller one.
Consider the roll gap adjustment method: Hydraulic adjustment is superior to manual shims, allowing for rapid, online adjustment of output particle size and reducing downtime.
Confirm voltage and spare parts before ordering: Verify local voltage/frequency, the list of wear parts, and delivery lead times to avoid production stoppages while waiting for parts.
VII. Recommended Related Equipment
Double-roll crushers are typically used for secondary or fine crushing stages and can be combined with the following equipment to form a complete production line:
• PE Series Jaw Crusher: Performs primary crushing to reduce large ore blocks to under 100mm, providing suitable feed for the double-roll crusher;
• YK Series Vibrating Screen: Screens and classifies crushed material; oversized material is recirculated for re-crushing, creating a closed-loop circuit;
• Double-Roll Sand-Making Machine / PFL Vertical Compound Crusher: Can be used in series after the double-roll crusher when higher fineness or sand production is required;
• ZSW Vibrating Feeder and Belt Conveyor: Ensure continuous, uniform feeding to maintain the double-roll crusher's full-load operation.
VIII. FAQ
1. How much does a double-roll crusher cost?
Prices vary based on model, motor power, and roll surface material: the 2PG400×250 model costs approximately 30,000–80,000 RMB, while the 2PG1200×800 model costs approximately 200,000–400,000 RMB. Bacihy offers comprehensive package pricing for entire production lines, with transparent costs for shipping, installation, and commissioning; a payment structure of "30% deposit + 70% pre-shipment payment" is available.
2. What is the difference between a double-roll crusher and a jaw crusher?
Jaw crushers are suitable for the primary coarse crushing of large materials (handling feed sizes exceeding 1,000 mm). In contrast, double-roll crushers typically accept feed sizes of no more than 100 mm but offer precise control over output size (ranging from 2 mm to 50 mm) and result in a lower rate of over-crushing (production of fines). They serve complementary roles in the production process rather than acting as substitutes for one another.
3. Can double-roll crushers process materials with high moisture content?
Yes. Double-roll crushers operate based on compression and shearing principles rather than impact forces. They are resistant to clogging when processing sticky, moist materials (such as wet coal or gypsum) with moisture content between 10% and 15%. When equipped with a scraper device to clean the rolls, they ensure stable operation—a significant advantage over hammer crushers and impact crushers when handling wet materials.
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.
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