Double-Toothed Roll Crusher: 2PGC Series Solution for Medium-to-Fine Crushing of Coal and Coke

Double-Toothed Roll Crusher

The double-toothed roll crusher (2PGC series) employs two counter-rotating, toothed roll surfaces to crush material through a combination of shearing and compression. It is specifically designed for the medium-to-fine crushing of brittle materials with low-to-medium hardness (such as raw coal, coke, coal gangue, limestone, gypsum, and rock salt). A single unit can accept large lumps up to 800mm and reduce them to under 150mm in a single pass. It typically maintains a fines generation rate of less than 10% and consumes approximately 30% less electricity per ton compared to hammer crushers; furthermore, it is naturally suited for handling wet, sticky materials with moisture content up to 15%. For coal preparation plants, coking plants, and power plants—where product value is determined by particle size and fines represent a financial loss—the double-toothed roll crusher is a key piece of equipment for reducing costs per ton and maximizing the value of the final product.

I. What is a double-toothed roll crusher?

The double-toothed roll crusher belongs to the "toothed roll" category of the roll crusher family. While it shares the same frame platform as smooth-roll crushers, it differs in that its roll surfaces feature regularly arranged teeth, created through casting or hard-facing (weld overlay). During operation, material falls between the two rolls; the counter-rotating toothed rolls grip the lumps and draw them into the crushing gap. The tooth tips exert concentrated shear forces while the roll bodies apply compressive forces, tearing the material apart along its natural joints and fractures. The crushed product is then continuously discharged from beneath the roll gap. The output particle size is determined by both the roll spacing and the tooth profile, resulting in uniform particles and minimal flake-like material.

Three key aspects of the working principle:

• Low speed, high torque: Rotational speed is significantly lower than that of hammer or impact crushers, resulting in lower impact loads, reduced vibration and noise, and savings on foundation investment;

• Shear-dominant action: Tearing by tooth tips replaces high-speed impact, minimizing fines generation and maximizing the yield of lump coal and high-value product;

• Forced discharge: The tooth profile on the roll surface acts as a conveyor, continuously discharging material as the rolls rotate and preventing the crushing chamber from clogging.

Fundamental Differences from Hammer Crushers and Jaw Crushers

Hammer crushers rely on high-speed impact to pulverize material, resulting in significant loss of fines when processing coal or coke—commodities priced based on particle size. Jaw crushers rely on compression; while suitable for the primary crushing of hard rock, they produce inconsistent output sizes and have high rates of over-pulverization. The double-toothed roll crusher strikes a balance between the two: it handles large lumps, offers controllable output size, and minimizes over-pulverization—qualities that have made it the industry-standard choice for coal and coke processing.

toothed roll crusher

II. Typical Application Scenarios

• Coal Preparation/Washing Plants: Coarse to medium crushing of run-of-mine coal, lump coal, and gangue to 50–150mm. Replacing hammer crushers with this equipment increases the yield of lump coal, reduces the loss of fines, and improves recovery rates during washing;

• Coking Plants: Since coke and coke breeze are priced by size, over-pulverization represents a financial loss; the shearing action of toothed rolls keeps the over-pulverization rate below 10%;

• Power Plant Fuel Workshops: Crushing boiler-feed coal to 25–50mm; uniform particle size facilitates combustion control and reduces coal dust dispersion and calorific value loss;

• Building Materials & Chemicals: Precision granulation of limestone, gypsum, calcium carbide, rock salt, and clay; stable output size benefits downstream grinding processes;

• Metallurgy & Solid Waste: Pre-crushing of sinter, furnace slag, and steel slag, as well as coarse crushing of brick and concrete construction waste, providing consistent particle sizing for magnetic separation and screening processes.

III. Core Advantages of Double-Toothed Roll Crushers

1. Low over-pulverization rate translates directly into profit: Low-speed shearing results in an over-pulverization rate of <10%. Compared to the 18%–25% fines content produced by hammer crushers, this allows for the retention of an additional 5–15% of usable lump material for size-priced coal and coke, resulting in a substantial cumulative increase in annual revenue.

2. Handles large lumps in a single unit, simplifying the production line: Accepts feed sizes up to 800mm, allowing run-of-mine coal from open-pit operations to be fed directly into the machine. This eliminates the primary coarse crushing stage and reduces investment in storage bins, conveyors, and civil infrastructure, resulting in a more compact production line.

3. No clogging with wet, sticky material: The combination of a toothed roll surface and a scraper mechanism ensures continuous operation even with wet coal (10%–15% moisture) or muddy gangue, preventing downtime during rainy seasons or high-moisture conditions.

4. Dual hydraulic and spring protection: Automatically retracts to discharge uncrushable objects—such as iron scraps or roof bolts—and quickly resets. This protects the roll teeth and motor, preventing jams and motor burnout.

5. Low maintenance costs: Features no hammer heads or high-speed rotors. The roll shells are made of high-manganese steel or alloy hard-facing material; worn surfaces can be restored via on-site hard-facing 2–3 times, with each restoration costing only 20%–30% of a new replacement.

IV. Technical Parameters (Typical Configuration for 2PGC Series)

Note: Capacity is rated based on raw coal (bulk density approx. 0.8–1.0 t/m³); for lightweight materials such as coke or coal gangue, a conversion factor of 0.45–0.55 applies. Please provide details on material lithology, moisture content, and target particle size; Baichy Heavy Industry offers one-on-one model selection and test-run support.

Double-Toothed Roll Crusher

V. Application Cases

Case 1: Raw Coal Primary Crushing Retrofit at an Inner Mongolia Coal Preparation Plant. The plant originally used a hammer crusher for lump coal; hammer heads required monthly replacement, and the lump coal yield was under 70%. After switching to the 2PGC900×900 double-toothed roll crusher, raw coal (≤800 mm) was fed directly into the machine with a discharge size of ≤150 mm. Lump coal yield rose to over 85%, electricity consumption per ton dropped by approximately 32%, the roll tooth hard-facing repair cycle extended to 6 months, and annual maintenance costs decreased by nearly 40%.

Case 2: Sinter Crushing at a Southeast Asian Steel Plant. A sintering plant belonging to a steel group required a discharge size of ≤50 mm with a low fines generation rate. By adopting a 2PGC600×750 double-toothed roll crusher in a closed-circuit configuration with screening, the product particle size remains stable and the fines content is significantly reduced. The unit has operated continuously for 8,000 hours without requiring a major overhaul, and the comprehensive cost per ton has dropped by 25% compared to the previous hammer crusher setup.

Case Study 3: Sand-making pre-processing stage at a limestone mine in East China. The raw limestone had a high clay content, causing frequent chamber blockages in the original impact crusher. A 2PGC600×750 unit was installed upstream for primary crushing; the resulting material (≤50mm) was then fed into the impact crusher for shaping. This increased the production line's hourly output by approximately 20% and reduced downtime caused by clearing blockages by 70%.

Note: The above summarizes typical operating conditions; specific parameters vary based on material properties and site conditions. Please contact us for detailed technical proposals tailored to specific rock types.

VI. Related Recommended Equipment

The double-toothed roll crusher typically works in tandem with the following equipment to form a complete "feeding–crushing–screening–conveying" closed-loop system:

Vibrating Feeder (ZSW Series): Ensures uniform, continuous feeding; prevents large lumps from damaging the hopper; maintains full-load operation.

Jaw Crusher (PE/PEX/C Series): Performs primary coarse crushing of oversized raw ore to provide suitable feed for the toothed roll crusher.

Circular Vibrating Screen (YK Series): Handles closed-circuit screening and product grading to control output particle size.

Belt Conveyor + Iron Remover: Connects process stages and captures metal debris to protect the roll teeth.

Bag-type Dust Collector: Integrated dust removal for enclosed conveying systems; meets "Green Mine" and environmental impact assessment requirements.

VII. FAQ

Q1: What materials can the double-toothed roll crusher process? What is the maximum hardness limit?

It is primarily designed for brittle materials of low to medium hardness with a compressive strength below 150 MPa, such as raw coal, coke, coal gangue, limestone, gypsum, calcium carbide, rock salt, sinter, slag, and construction waste. It is not suitable for highly abrasive, hard rocks like granite or basalt—those are best handled by jaw crushers and cone crushers. Please provide data on material lithology and hardness before equipment selection.

Q2: Which produces less fines when crushing coal: the double-toothed roll crusher or the hammer crusher?

The double-toothed roll crusher. Hammer crushers rely on high-speed impact, resulting in a fines rate typically ranging from 18% to 25%; in contrast, toothed roll crushers utilize a combination of shearing and compression, keeping the fines rate below 10%. For coal and coke priced based on particle size, a 5-percentage-point reduction in the fines rate translates to retaining 5% more marketable lump material per ton—resulting in a substantial difference in cumulative annual revenue.

Q3: How is the discharge particle size adjusted, and what happens when the toothed rolls wear down?

Discharge particle size is controlled by adjusting the gap between the two rolls using a hydraulic system or shims, allowing for adjustments within the 25–150mm range based on operating conditions. The roll shells are made of high-manganese steel or alloy hard-facing materials, offering a service life of 6–12 months for coal and coke applications. Once worn, they can be restored via on-site hard-facing repair 2–3 times; the cost of a single repair is only 20%–30% of the price of a new roll. Baichy Heavy Industry provides genuine roll shells and hard-facing process support, preventing the need to scrap the entire roll assembly.

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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