Comparison of Mineral Sizer and Roll Crusher and Analysis of Common Faults

Overview

Sizer crusher is mainly used for coarse, medium and fine crushing operations of medium-hard materials such as coal and coke. It has the characteristic of wide adaptability and has a good adaptability to materials with high viscosity and high moisture content. Although the two types of double-roller crushers, Mineral sizer and roll crusher, differ in structure and processing capacity, both have the dual functions of crushing and classification.

They can not only strictly ensure the particle size of the product, but also achieve a very low over-crushing rate. The particle size of the product is adjustable, and they are equipped with stable and reliable mechanical and automatic control protection devices. It features low vibration, low noise and little dust.

Two working principles of crushers

The crushing principle of Mineral sizer

The materials are fed into the crushing chamber from top to bottom through the upper chute. The two toothed rollers with crushing heads rotate towards each other, directly screening out the materials smaller than the product particle size through the comb plate. Under the shearing and squeezing action of the two rotating crushing heads, the large pieces of materials are crushed to obtain raw coal with an output particle size within a certain range.

The crushing principle of Roll crusher

It is composed of a fixed crushing roller, a mobile crushing roller and two cylindrical rollers that rotate relatively. The material enters the crushing chamber from the top and is pulled into the gap between the two rollers under the friction with them. It is crushed by compression and the crushed material is discharged under the action of gravity.

Comparison of the structures of two types of crushers

The structure of Mineral sizer

The drive unit of Mineral sizer consists of two motors, two hydraulic couplings, two reducers and two couplings, which are respectively connected to two crushing toothed rollers. The basic support part is composed of a casing and a base. The casing is made up of side plates and baffles with sparse teeth. The outer edges of the side plates and baffles are aligned and closed together to form a box-shaped crushing cavity.

The structure of Roll crusher

The transmission device of a Roll crusher is usually composed of a motor and a pulley, etc. The crushing roller has two parts: the driving roller and the driven roller. The driving roller is directly driven to rotate by the transmission device, and the driven roller works in coordination with the driving roller. Bearings and bearing housings are used to support the rotating shaft of the roller.

The performance of Mineral sizer

Power transmission protection

The motor output end of Mineral sizer is equipped with a hydraulic coupling, which can effectively prevent the impact on the reducer and the main shaft during the hard start of the system, significantly reducing the loss during the equipment start-up stage. When a blockage accident occurs in the Mineral sizer and is not detected in time, the coupler will increase in temperature due to excessive load, causing the fusible plug to melt. At this point, the motor enters an idling state, fundamentally protecting the motor from damage and ensuring the safety of the core power components of the Mineral sizer.

Material handling efficiency and classification

The side plate body of the crushing chamber of Mineral sizer is equipped with a toothed plate. When the material enters the crushing chamber, the toothed plate can directly screen out the material that is already within the output particle size range. The material that needs further crushing enters the crushing process. Mineral sizer simultaneously has the dual functions of crushing and classification, improving the overall efficiency of material processing It has reduced unnecessary energy consumption for crushing.

Crushing principle and environmental protection performance

The crushing principle of Mineral sizer is characterized by one-time crushing. After crushing, the material can be directly discharged without multiple processing steps. This enhances the working efficiency of the Mineral sizer, and also ensures that the entire machine operates with low vibration and noise, while generating relatively less dust.

Equipment maintenance

The rack of Mineral sizer is equipped with a centralized lubrication device. This device will supply lubricating grease to the bearing components of Mineral sizer in a timely manner according to the preset cycle and dosage, ensuring that the bearings are always in a good lubricated state during operation, reducing the friction loss of the bearings, extending the service life of the bearings, and lowering the maintenance costs and downtime of Mineral sizer.

The convenience of equipment maintenance

The frame of the Mineral sizer is equipped with a walking device, which facilitates the maintenance work of the Mineral sizer. When it is necessary to inspect, repair or replace the internal components of the equipment, the staff can move the Mineral sizer through the walking device and adjust the position of the equipment without the need for large lifting equipment It has reduced the difficulty of maintenance operations and saved maintenance time.

Structural protection and durability

The modular design of Mineral sizer features a neat and standardized structure. Moreover, key transmission components such as couplings and couplings are equipped with dust-proof devices, which can effectively prevent external dust and impurities from entering the interior of the couplings and couplings, avoiding wear and tear on the components or affecting the transmission efficiency caused by dust, and ensuring the stable operation of the Mineral sizer transmission system.

Analysis of Common Faults of Two Types of Crushers

The safety pin of Roll crusher is cut off

The cause of the malfunction is material blockage, the presence of ironware in the feed, and a sudden increase in the feed volume. The solution is to replace the safety pin.

The Mineral sizer motor is idling

The cause of the malfunction was that the material blockage was not detected in time, and the coupler was disconnected from the motor. The solution was to replace the fusible plug, reverse the motor, and manually remove the material blockage.

The Mineral sizer reducer makes abnormal noises and the temperature rises

The cause of the malfunction is lack of lubrication or wear of the gears. The solution is to open the upper cover of the reducer and check the vernier scale to see if there is a lack of lubricating oil. Check whether the gears are severely worn.

The temperature of the bearing rises

Faults that may occur in both Mineral sizer and roll crusher are caused by too small bearing clearance, lack of lubrication, poor sealing, and bearing wear. The solution is to add oil for lubrication. If there is no obvious effect, remove the bearing to check the sealing condition and whether the bearing is worn. If both the shaft and the bearing are worn, then consider possibly replacing the machine.

The output particle size continues to increase

Both Mineral sizer and roll crusher malfunctions may occur. The cause of the malfunction is the wear of the crushing teeth. The solution is to first adjust the center distance of the tooth roller. If the effect is not obvious, surfacing the tooth head or replacing the tooth disc, tooth plate or shaft.

Summary

Two types of crushers, mineral sizer and roll crusher, were compared. Their crushing principles are similar, but they each have their own characteristics in structure and technical features. Their processing capacity and requirements for feed particle size are also different, which has certain guiding significance for how to select crushers on site.