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Controlled Crushing with Adjustable Roll Gap
LIPU roll crushers are designed for controlled crushing of brittle and medium-hard materials through compression between two rotating rolls.
They are commonly used where relatively uniform product size, adjustable discharge and reduced over-crushing are important. Typical applications include limestone, coal, dolomite, clinker, coal gangue, river pebble and other suitable materials.
LIPU provides double roll, toothed roll and hydraulic roll crusher configurations for different feed characteristics and product size requirements.
A roll crusher reduces material by passing it between two counter-rotating rolls.
As the rolls rotate toward each other, material entering the crushing chamber is gripped, compressed and broken before passing through the adjustable gap between the rolls.
Compared with impact-based crushing, roll crushing is better suited to applications where:
Roll crushers can be used for primary, secondary or fine crushing depending on roll diameter, tooth profile, feed size and gap setting.
Different roll surfaces and adjustment systems are used for different materials and crushing duties.
A double roll crusher uses two smooth or lightly profiled rolls rotating toward each other.
It is suitable for:
The discharge size is mainly controlled by the gap between the two rolls.
Double roll crushers are commonly used where a relatively consistent product size is required.
A toothed roll crusher uses rolls equipped with teeth or crushing segments.
The tooth profile improves material gripping and allows the crusher to handle larger or more irregular feed.
Typical applications include:
The tooth shape and spacing should be selected according to feed characteristics and required discharge size.
A hydraulic roll crusher uses a hydraulic adjustment or protection system to control the roll gap and respond to overload conditions.
Compared with a purely mechanical adjustment system, hydraulic control can simplify discharge adjustment and provide more flexible operating control.
It is suitable where:
The final configuration depends on crusher size and project requirements.
Roll crushers can process a wide range of brittle and medium-hard materials.
Typical materials include:
Not every material is equally suitable for every roll crusher configuration.
For example:
Typical applications include:
For larger primary feed, a Jaw Crusher may be used upstream before the roll crusher.
Material is fed into the space between two rotating rolls.
The rolls rotate inward and draw the material into the crushing zone.
The working process can be summarized as:
The final product size is influenced by:
Stable and even feeding helps improve product consistency.
A typical roll crusher includes:
The exact structure varies between double roll, toothed roll and hydraulic roll crusher designs.
Roll gap adjustment is one of the most important features of a roll crusher.
The distance between the two rolls determines the minimum passage size through the crushing chamber.
A smaller gap generally produces a finer product, while a larger gap allows coarser discharge.
However, the actual finished size also depends on:
For stable product size, the roll gap should be checked regularly because wear on the roll surface can gradually change the effective discharge opening.
Hydraulic or mechanical adjustment systems can be used depending on the crusher configuration.
| Model | Feed Size (mm) | Discharge Size (mm) | Capacity (t/h) |
|---|---|---|---|
| 2PG400×250 | <35 | 2–8 | 2–10 |
| 2PG400×400 | <35 | 2–8 | 5–12 |
| 2PG610×400 | <65 | 2–20 | 5–20 |
| 2PG750×500 | <75 | 2–25 | 10–40 |
| 2PG800×600 | <80 | 2–25 | 12–45 |
| 2PG1000×700 | <100 | 3–30 | 20–65 |
| 2PG1200×800 | <120 | 3–35 | 35–80 |
| 2PG1500×800 | <130 | 3–45 | 50–120 |
| 2PG1600×1000 | <150 | 3–50 | 60–140 |
Actual production capacity depends on material properties, feed distribution, roll gap and operating conditions.
For project selection, LIPU should confirm the complete parameter set including motor power, equipment weight and installation dimensions.
A roll crusher should be selected according to material characteristics and the required final product rather than capacity alone.
Important project information includes:
A smaller roll gap and suitable smooth-roll configuration may be preferred.
A toothed roll crusher can provide better gripping performance.
A hydraulic adjustment system can provide more convenient roll gap control.
Roll surface wear should be considered carefully because wear can affect both operating cost and discharge size stability.
The final selection should balance capacity, wear resistance, feed size and product size requirements.
LIPU Heavy Industry provides crushing, screening and mineral processing equipment for mining, aggregate, cement and industrial material processing projects.
For roll crusher projects, LIPU can assist with:
Roll crushers can also be integrated with feeders, conveyors, screens and other crushing equipment to form a complete material processing system.
What materials are suitable for a roll crusher?
Roll crushers are mainly suitable for brittle and medium-hard materials such as limestone, coal, dolomite, clinker and coal gangue. Suitability for harder and more abrasive materials depends on the specific roll crusher design.
What controls the discharge size of a roll crusher?
The main factor is the gap between the two rolls. Roll surface profile, feed size, material hardness and roll wear also affect the final product size.
What is the difference between a smooth roll crusher and a toothed roll crusher?
A smooth roll crusher mainly uses compression and is suitable for controlled crushing of brittle materials. A toothed roll crusher provides stronger gripping action and can handle larger or more irregular feed.
Can a roll crusher produce fine material?
Yes. Fine discharge can be achieved by reducing the roll gap, but the practical product size depends on crusher model, material properties and roll surface condition.
What information is needed to select a roll crusher?
Provide the material type, maximum feed size, required capacity, target discharge size, hardness, abrasiveness and moisture condition. These factors determine the roll diameter, roll surface and crusher configuration.
We provide a variety of mining and processing equipment, including feeders, rock crushers, grinders, classifying and screening machines, washing machines, gravity separators, flotation machines, magnetic separators, electric separators, dewatering equipment and laboratory mineral processing equipment.
