What is the Difference Between a Twin Shaft Mineral Sizer and a Single Roller Crusher

Introduction

Mineral sizer and single roller crusher have significant differences in several aspects. In terms of structure, the mineral sizer adopts a dual-axis design, equipped with two relatively rotating rollers, while the single-roller crusher has only one rotating roller. This structural difference leads to the different working principles of mineral sizer and roller crusher.

And there are also differences between the two in terms of application fields.Mineral sizer is widely used in industries such as mining, metallurgy, building materials, and chemical engineering due to its unique crushing principle and adaptability, especially in situations where viscous materials need to be processed and the particle size of the crushed materials must be strictly controlled. Single-roller crushers, on the other hand, are more often used in the primary crushing stage, such as breaking large pieces of material into smaller particles, providing convenience for subsequent processing.

Now let’s analyze the differences between the two.

Transmission principle and structure

Twin Shaft Mineral Sizer

Mineral Sizer is generally driven by two motors to rotate two crushing rollers in opposite directions. The Twin Shaft structure enhances the crushing efficiency and also strengthens the stability and durability of the equipment. Structurally, the crushing rollers of mineral sizer are mostly made of high-strength alloy steel, with wear-resistant teeth or grooves on the surface to ensure the crushing effect during long-term operation. Moreover, the mineral sizer is equipped with a centralized lubrication device and an automatic control system, enabling the equipment to operate automatically and be remotely monitored.

Single roller crusher

The structure of the single-roll crusher, its transmission principle is that the motor drives the roller shaft of the single-roll crusher to rotate through the hydraulic coupling, cycloidal pinwheel reducer and pin coupling, thus making the toothed roller rotate continuously. After the material enters the machine body through the feed port, it is split and squeezed between the toothed roller and the vibrating plate. The rationality of the design of the main components such as the toothed roller and the forehead plate directly affects the crushing efficiency and capacity of the crusher.

Application and Principle

Twin Shaft Mineral Sizer

Twin Shaft Mineral Sizer is mainly applied in primary crushing and secondary crushing operations. Unlike single-roll crushers, mineral sizer consists of two relatively rotating crushing rollers with a certain gap between them, and the surfaces of the rollers are usually equipped with wear-resistant teeth or grooves to enhance the crushing effect. It is suitable for crushing materials of various hardness and viscosity, including ores, coal, coke, slag, etc.

In mineral sizer, materials are crushed through the gap between two rotating rollers. The crushing process mainly includes shearing, tearing and squeezing. As the roller rotates, the material is gradually brought into the gap and subjected to intense crushing. The crushed materials are discharged through the discharge port at the bottom, and their particle size can be controlled by adjusting the gap between the rollers. Due to its double-roller structure, mineral sizer can achieve higher crushing efficiency and more uniform particle size distribution.

Single roller crusher

The single-roll crusher is composed of a toothed rotating roller and adjustable screen plates. It is mainly applied in coarse and medium crushing operations, used to crush brittle materials with a stress not exceeding 20kN/cm ². It is not suitable for crushing sticky materials such as clay. In the brick and tile industry, it is mainly used to crush hard materials such as shale and coal gangue.

The crushing process of materials in a single-rod crusher is a splitting and extrusion process. When materials enter the single roller crusher from above, they are carried into the gap between the rollers and the fluorine plates by the rotating rollers for crushing. The crushed materials are discharged under the effect of their own weight. The particle size of the crushed material can be controlled by adjusting the gap between the particle plate and the roller. The particle size after crushing is ≤25mm.

The form of teeth on the toothed stick

Twin Shaft Mineral Sizer

The teeth (or tooth tips) of the Primary mineral sizer are usually strong and durable, spaced relatively large, and arranged in a meshing manner between two counter-rotating shafts. This meshing design ensures that large pieces of material are clamped and crushed through a combination of impact force, shear force and compressive force. The teeth can be arranged alternately or in a crisscross pattern along the axis length to prevent the material from flowing around and ensure uniform crushing. The tooth tips are usually hardened (for example, by using wear-resistant alloys) to withstand the wear of hard materials.

The teeth of Secondary mineral sizer are smaller and more closely arranged, aiming to achieve a finer crushing effect. These tiny teeth have also undergone hardening treatment to ensure wear resistance and stability during long-term operation. In Secondary mineral sizer, the closely arranged and interlaced design of the teeth helps to provide a more uniform crushing effect when the material passes through, thereby achieving stricter particle size control.

Single roller crusher

Spaced arrangement type. Rows of roller teeth (tooth plates) are arranged at intervals in both the axial and circumferential directions on the cylindrical surface of the roller teeth. The advantage of this is that large pieces of material are prone to being bitten, which is conducive to improving the crushing efficiency. And the tooth plate is firmly and reliably fastened on the shaft. Its disadvantages are that the particle size after crushing cannot be strictly controlled and the equipment is prone to being stuck by hard foreign objects such as stones and metals.

Involute distributed. On the cross-section, the roller teeth are distributed in an involute pattern along the circumference; on the axial cross-section, the roller teeth are regularly staggered in height. Its prominent advantage is that it is not easily jammed by hard materials, but its ability to bite into large pieces of materials is not as good as that of the spaced arrangement type.

Summary

When choosing between mineral sizer and roller crusher, factors such as the nature of the material, processing capacity, crushing particle size requirements and equipment maintenance costs need to be considered. Due to its dual-shaft design and fine tooth arrangement, Mineral sizer is more suitable for handling sticky materials and applications that require strict particle size control, offering higher crushing efficiency and a more uniform particle size distribution. When choosing equipment, a comprehensive consideration should be made based on specific application scenarios and requirements.