Marcy Double Roll Crusher, 6.5 x 6in, Max. Feed 3,000 lbs

Marcy Double Roll Crusher, 6.5 x 6in, Max. Feed 3,000 lbs

Double Roll Crushers do single pass size reduction of medium hard to hard materials like rock or ore to a minus 10 mesh within the crushing chamber. The crusher will process various feed materials and the characteristics of those materials (size and hardness) will affect performance. Topsize is approximately 1/2in and final fineness is typically a No. 10 (2mm) opening depending on material. Output size is controlled by adjusting the gap between the rolls with a hand lever so you can get the size you want. Roll Crushers work well for preparing samples for further fine reduction with a pulverizer. The interaction between the fixed roll and the moving it is critical for material reduction so an optimal gap is maintained. Some roll crushers have corrugated surfaces on the rolls for coarse or sticky materials. The roll surface (smooth, corrugated or toothed) affects the gripping and crushing. The floating roll mechanism allows for better handling of uncrushable materials and reduces the chance of choking during operation. Feed hoppers have high capacity, open easily for cleaning and maintenance access and have an electrical safety interlock that shuts off power to the unit when the hopper is opened. The final crushed material is ready for further processing or analysis.

Crushers are rugged and easy to operate for lab and pilot plant use. Double Roll Crushers are mounted on a steel base, have relief springs and are fully guarded. These are heavy duty machines for heavy duty applications. Crushers are fabricated steel with a steel drive guide for operator safety. Tilt design feed hopper, Ni-hard facings for long life, relief springs and heavy duty pillow block bearings. The design has a crushing plate that works along with the rotating rolls, applying shear and compression forces to get consistent size reduction.

• 6.5x6in (165x153mm), Dia.xW

• 304 stainless steel crushing rolls with Ni-hard roll facings.

• 2hp TEFC motor with V-belt drive

• Uniform speed throughout crushing

• Reduces most rock-like materials of 0.5in (13mm) maximum feed size to minus No. 10 (2mm) at 3,000lbs (1,361kg) per hour.

• The max feed size is important for selecting the crusher for specific materials, ensuring efficient operation and desired reduction ratios. 60Hz.

• Voltage 230V or 460V must be specified at time of order.

Roll crushers are a versatile and efficient reduction machine that crushes material by passing it between two rotating rolls. Compared to other crushers such as jaw or cone crushers, roll crushers offer unique advantages in handling medium hard materials and producing uniform product sizes with less fines.

Rolls are made of durable steel and rotate in opposite directions to create crushing action. Output size is controlled by the gap width between the rolls. The efficiency of roll crushers is often measured by their reduction ratio, which indicates the maximum size reduction achievable in a single operation and is crucial for evaluating performance.

Roll crushers are used in many industries including mining, cement, and coal to reduce materials to 0-25mm. Standard roll crushers are typically used in secondary crushing stages, especially when the feed size is limited to about 50 mm, and are not suitable as primary crushers for hard ores. They are also great for preliminary crushing of moist clay before drying and are an essential tool in many processes.

Some roll crushers can be configured for single stage crushing, providing primary reduction in one step. Certain designs, such as triple and quad roll crushers, can achieve the desired size reduction in one pass, increasing processing efficiency. When describing the rolls, smooth rolls are commonly used for materials like limestone and coal, offering effective reduction for these applications.

How They Work

Roll crushers work by a combination of impact, shear and compression forces to break down the feed material. As the material enters, it is immediately impacted by the rotating and the crushing process begins. The compression forces come into play as the material is drawn between the crushing rolls which turn towards each other. This action confines the crushing to the area where the teeth of the rolls mesh so a consistent and effective reduction of the material. Toothed rolls are often used for finer reduction, especially with coal and other soft materials, as they help prevent clogging and enhance throughput. Different tooth patterns can be selected to optimize product shape and minimize fines depending on the application. Both rolls are synchronized to run at the same speed so a true and efficient crushing action is maintained throughout the process. In some designs, the rolls are rigidly fixed to the frame, allowing for precise gap control, which is essential for fine grinding applications. This combination of forces makes roll crushers good for reducing a wide range of items.

Types

Roll crushers come in several types each designed for specific applications and reduction ratios. The single is commonly used as a primary crusher, especially in coal processing, and has a 6:1 crushing ratio. It is ideal for reducing large friable materials in a single stage. Some roll crushers are designed for single stage crushing, while others can be configured for multi-stage reduction to achieve finer product sizes. Double roll crushers have a 4:1 ratio and can be used as primary and secondary crushers. They often feature rolls for enhanced reduction and are designed to handle different material, producing a more uniform particle size. Triple roll crushers have a 6:1 ratio on the top stage and 4:1 on the bottom stage, and are versatile for primary and secondary crushing, with toothed rolls available for improved performance. Quad roll crushers have a 4:1 ratio on both top and bottom stages and are used for primary and secondary crushing of tougher items.

Customization includes selecting different tooth patterns for the rolls, which are chosen based on the material being processed to optimize product shape and minimize fines. Each type is designed to meet specific needs for efficient and effective material reduction in many industries.

Features:

• Heavy duty pillow block bearings for smooth and low maintenance operation

• Safety interlock shuts down power when hopper is lifted and safety guards cover moving parts

• Single hand lever for gap adjustment

• Steel construction

• Base mounted

• Spherical roller bearings for smooth and low maintenance operation self aligning and grease lubricated

Feed Material:

Maximum Particle Size  0.5in (13mm) — For sample preparation, consider using a Soil Grinder for Sample Preparation.

Max. Feed Capacity 3,000lb (1,361kg) per hour

Final Size  Minus No.10 (2mm)

Material  304 stainless steel facings 6.5 x 6in (165 x 153mm) Dia.xW

Application  rocks, ores, minerals

Electrical  230/460V / 60Hz, 2hp / 3 Phase

Dimensions 50 x 38 x 32in (127 x 97 x 81cm) WxDxH

Industry Applications

Roll crushers are used in many industries because of their ability to process friable materials and soft materials with minimal fines generation. In mining, double roll crushers are used for primary and secondary crushing of coal, limestone and other minerals to get consistent reduction for further processing. Power generation industry uses roll crushers for crushing coal and burnt lime to support efficient fuel handling and combustion. Construction and recycling industry uses roll crushers for high capacity crushing of salt, gypsum, shale and recycled aggregates. Roll crushers are rugged and low horsepower machines and can be used for continuous heavy duty operation and can be used as crushers. Single roll crushers are used for tertiary crushing to provide additional processing and reduction of size where needed. Whether in cement production, mineral processing or power generation, roll crushers deliver reliable performance and long life.

Construction and Maintenance

Roll crushers are built to last with rugged construction that can withstand continuous operation. The crushing rolls are made of high strength steel or other wear resistant materials and are designed to be replaceable for extended life and easy maintenance. The frame is rigidly constructed to provide stable vibration free operation even under heavy loads. Maintenance is easy with self-aligning spherical roller bearings that require minimal attention and replaceable segments that can be quickly accessed and swapped out as needed. Regular bearing lubrication and cleaning of the crushing chamber will maintain optimal performance and prevent premature wear. With these features roll crushers are built for long term operation with minimal downtime.

Operation and Safety

Roll crushers are designed for easy and safe operation for both experienced operators and new to crushing equipment. Controls are simple with a start/stop button and emergency stop switch for immediate shutdown if needed. The chamber is designed with safety in mind with a floating roll that allows uncrushable objects to pass through without damage. This design not only protects the machine but also minimizes the risk of operator injury. To operate safely users should follow recommended safety procedures such as wearing personal protective equipment and keeping the area around clear of obstructions. Regular inspection and maintenanc will enhance safety and prevent accidents and ensure safe operation at all times.

Troubleshooting

While roll crushers are reliable, issues can occur. Uneven wear on the rolls is common due to misaligned rolls or inconsistent feed material. Adjust the alignment and feed rate to fix this. Excessive vibration means loose or worn out bearings, tighten or replace to get smooth operation. Blockages in the chamber occur when non-crushable or oversized feed enter it; clear them out and adjust the feed size to prevent recurrence. Regular maintenance including inspection and bearing inspection and cleaning of the chamber will prevent these issues and ensure safe and efficient operation.