Roll Crusher for Coal & Slag
For coal, coke, slag, clay or clinker (medium-hard, below 150 MPa), a roll crusher beats hammer and impact crushers on three points: fines under 10%, no clogging at 10–15% moisture, and discharge adjustable from 2 to 50 mm.
What Is a Roll Crusher and How Does It Work?
A roll crusher reduces material by compression and shear between two counter-rotating rolls — no high-speed impact — so particles break along natural fracture lines, fines stay low, wet feed does not clog, and output stays controllable.
• Smooth roll crusher (2PG) — coal, coke, clinker; output 2–50 mm.
• Toothed roll crusher (2PGC) — block coal up to 300 mm, sheared in one pass.
• Four-roll crusher — two stages in one machine, producing 0–3 mm fine sand.
Where Is a Roll Crusher Used? Key Applications
| Application | Feed | Output | Why It Wins |
|---|---|---|---|
| Coal preparation | Run-of-mine coal ≤300 mm | 0–50 mm | Fines below 10%; no dust-explosion risk |
| Coke crushing | Lumps ≤200 mm | 0–25 mm | Minimal powder protects sinter value |
| Slag & clinker recycling | Blast furnace slag | 0–10 mm | Smooth rolls resist abrasion |
| Clay & wet ore | 10–15% moisture | 0–30 mm | Scraper rolls never clog |
| Fine sand making | 0–30 mm limestone | 0–3 mm | Four-roll setup cuts a grinding stage |
6 Advantages That Make a Roll Crusher Stand Out
Low over-crushing, higher yield. Impact crushers make 18–25% fines; a roll crusher stays under 10% — 4–7 more saleable tons per hour on a 50 t/h line.
Wet, sticky feed is no problem. At 10–15% moisture, scraper rolls keep running while hammer crushers stop for cleaning.
Discharge set by the roll gap — adjustable. Hydraulic control holds ±1 mm; change spec in ~10 minutes.
Lower energy cost. Low-speed compression uses about 30% less electricity than impact crushing.
Shells last and are repairable. Mn18Cr2 shells run 6–8 months; weld build-up costs 20–30% of new.
Tramp iron protection. Hydraulic retraction reacts in 0.2 s, protecting rolls and uptime.
2PG roll crusher, coal crusher, coke crusher
Roll Crusher Specification Table (2PG / 2PGC Series)
| Model | Roll Diameter × Length (mm) | Max. Feed Size (mm) | Discharge Size (mm) | Capacity (t/h) | Motor Power (kW) |
|---|---|---|---|---|---|
| 2PG400×250 | 400×250 | ≤25 | 2–8 | 5–10 | 11 |
| 2PG610×400 | 610×400 | ≤40 | 10–30 | 15–40 | 30 |
| 2PG750×500 | 750×500 | ≤45 | 10–40 | 30–60 | 37 |
| 2PG900×700 | 900×700 | ≤60 | 10–50 | 50–120 | 45–55 |
| 2PGC600×750 (Toothed Roll) | 600×750 | ≤200 | ≤50 | 40–80 | 2×22 |
| 2PGC900×900 (Toothed Roll) | 900×900 | ≤300 | ≤50 | 80–160 | 2×37 |
Real-World Case: 40 t/h Coal Preparation Line in Southeast Asia
A coal trader replaced an impact crusher losing 18% of output to fines and jamming weekly in the rainy season. Baichy supplied a 2PG750×500 double roll crusher (37 kW, gap 10–30 mm). After 3 months: fines (<3 mm) fell from 18% to under 8%; zero blockages at 12% moisture; electricity per ton down ~28%; shell wear 7 mm after 4,000 hours.
Typical configuration — actual figures vary with feed quality.
Recommended Equipment to Pair With Your Roll Crusher
| Stage | Recommended Machine | Why |
|---|---|---|
| Primary crushing | PE jaw crusher | Reduces 500 mm rock to ≤60 mm for the roll crusher feed limit |
| Coarse block coal | 2PGC toothed roll crusher | Shears 300 mm lumps in one pass |
| Screening | YK vibrating screen | Splits output by size; protects roll surfaces |
| Iron removal | Magnetic separator | Keeps tramp metal off the rolls |
| Downstream grinding | Ball mill / Raymond mill | Turns 0–10 mm product into powder |
Roll Crusher FAQ
Q1: What is the difference between a roll crusher and an impact crusher?
An impact crusher strikes material at high speed, generating 18–25% fines and struggling above 8% moisture. A roll crusher compresses feed slowly: fines stay under 10%, wet feed does not clog, and discharge size is set by the roll gap.
Q2: Can a roll crusher handle hard rock like granite or basalt?
No. Roll crushers suit medium-hard material below about 150 MPa — coal, coke, slag, clay, limestone, clinker. For granite, basalt or quartzite, use a jaw crusher or cone crusher.
Q3: How do I choose the right roll crusher model?
Match tonnage: 5–10 t/h → 2PG400×250; 15–40 t/h → 2PG610×400; 30–60 t/h → 2PG750×500; 50–120 t/h → 2PG900×700. Keep feed within 1/10–1/15 of roll diameter. Unsure? Send Baichy your material hardness, feed size and target output for a free sizing calculation.
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.
Baichy Heavy Industry – Your Trusted Partner
To ensure optimal performance of your equipment, Baichy Heavy Industry offers:
- Professional on-site installation guidance
- Comprehensive operator training
- 24/7 technical support & maintenance services
Our complete after-sales service system guarantees long-term, stable operation of your machinery with minimal downtime.
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To avoid scams and ensure authentic support, contact us exclusively through:
• Official Website: www.baichychina.com
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• Email: [email protected]
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