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Rolls crushers - PROC/ES

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Rolls crushers
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Rolls crushers, or crushing rolls, are still used in some mills today, although they have been replaced in most
installations by cone crushers. They can play a useful role with friable, sticky, frozen or less abrasive feeds.

In rolls crushers (spring rolls, dual-roll crushers), comminution takes place between two cylindrical rolls, each
rotating about a concentric horizontal shaft. In a single-roll crusher, crushing occurs between a rotating cylinder
and a stationary (straight or concave) plate. Roll surfaces may be smooth or finely corrugated or may be
provided with teeth, knobs or cutting edges. These can serve for primary crushing of soft to medium-hard
materials while corrugated rolls can be used for secondary and tertiary applications with medium-hard to hard
materials. Hard ores should be crushed with smooth rolls.
Crushing action is based largely on squeeze, to some extent on shear and with high-speed toothed-roll crushers,
also on impact. The smooth-roll (spring-roll) crusher is employed primarily in dry grinding or fine crushing of hard
and medium-hard rocks from 6 to 1.5 mm.



Rolls crushers - PROC/ES

Toothed roll crushers can serve in the primary crushing of medium-hard and soft rocks (coal, limestone,
asbestos, marl, gypsum, shale, etc.). When crushing wet and sticky, or soft and fibrous materials prone to
clogging, their performance surpasses that of all other equipment.

Figure 1

Figure 2



Rolls crushers - PROC/ES

The angle of nip formed between a particle and the roll surface is important in ensuring continuous flow of
material (Figure 1 above) and in establishing the maximum particle size (Figure 2 above) treatable. Except for
very large diameter rolls, the angle of nip limits the Reduction Ratio of the crusher. Since reduction ratios > 4:1
are rarely used, two stages are generally employed. The capacity of rolls crushing can be estimated from the
sheet of material that can pass between the two rolls:

In reality, true capacity is about 25 percent of this calculation because of voidage between the particles and
material slippage on the rolls surface.

This rule-based expert system is designed to transfer knowledge on unit operations and types of ores in
the field of mineral processing.

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