High-Capacity Double-Roll Crusher with 40% Lower Maintenance Costs
Double Roller Crusher Equipment Overview
The DL2GPX high-capacity double-roll crusher is specifically designed for large-scale crushing of minerals such as coal and calcium carbonate, with a single-unit processing capacity of 400–1,000 TPH. The equipment utilizes a combination of shearing, compression, and tensile forces for crushing, resulting in low energy consumption and high efficiency. The finished product block rate reaches 65%–80%, and raw material utilization is improved by 15%–30%. Each set of crushing teeth has a service life exceeding 3 million tons, reducing maintenance costs by 40% compared to traditional models. The external discharge adjustment mechanism allows for on-the-fly particle size calibration without shutdown. As a direct manufacturer, we offer customizable tooth profiles to meet specific needs. The machine is widely used in coal washing and beneficiation, calcium carbonate deep processing, and mineral raw material preparation.
Double Roller Crusher Equipment Highlights
- Triple-force synergistic crushing ensures low energy consumption and high efficiency, easily handling high-capacity operations of 400–1,000 TPH
- Lump rate of 65%-80%, improving raw material utilization by 15%-30% and significantly reducing over-crushing losses
- Uniform final product particle shape with excellent cubic structure, meeting the stringent requirements of downstream applications
- External discharge adjustment with mechanical locking allows for on-the-fly calibration of discharge precision
- Crushing tooth lifespan exceeds 3 million tons per set, reducing maintenance costs by 40%
- Direct supply from the manufacturer with customization options and full-cycle technical support
Double Roller Crusher Application Scenarios
- Crushing and classification of raw coal in large-scale coal washing plants, simultaneously producing lump coal and fine coal
- Primary crushing of calcium carbonate minerals such as calcite, limestone, and dolomite prior to grinding
- Crushing and screening of coal for thermal power plants to ensure uniform feed size
- Medium and fine crushing of fertilizer raw materials such as phosphate ore and potash ore
- Crushing and shaping of non-metallic minerals such as gypsum, shale, and clay
Double Roller Crusher Customized Process Flow
Taking an 800-ton-per-hour coal crushing line as an example: Raw coal silo → Plate feeder → Magnetic separator → DL2GPX double-roll crusher → Vibrating screen → Lump coal/fine coal classification + Recirculation closed-circuit
Double Roller Crusher Optional Configurations:
- Lump Coal Priority: Roll gap 40–80 mm, lump rate 75%–80%
- Fine Coal Priority: Roll gap 10–25 mm, multi-stage screening, fine coal proportion 60%+
- Calcium Carbonate Powder Production: Double-roll crusher + screening + vertical mill combination; crushing section capacity is 10%–15% higher than the grinding section
Double Roller Crusher Services
Solution Design: Material analysis, equipment selection calculations, process flow and investment analysis, delivering a comprehensive technical proposal
Equipment Manufacturing: In-house manufacturing by the original manufacturer; crushing tooth materials include high-manganese steel, alloy steel, and composite wear-resistant materials; custom tooth profiles and tooth counts available
Installation and Commissioning: On-site guidance by engineers until both production capacity and particle size meet acceptance criteria
Operation and Maintenance Management: Regular inspections, spare parts supply, operator training, and remote diagnostics; optional annual maintenance contracts
Double Roller Crusher Overseas Project Cases
Large-scale coal mine in East Kalimantan, Indonesia, with an annual raw coal production of over 8 million tons. In 2021, a technical upgrade replaced imported equipment with two DL2GPX-1200 double-roll crushers. Each unit achieves a production capacity of 700–720 TPH, with the lump coal rate increasing from 55% to 72%–75%. This resulted in an annual increase of approximately 750,000 tons of marketable lump coal and over $11 million in additional annual profit. Three years after commissioning, the first set of crushing teeth has processed over 3.2 million tons and remains in use, with maintenance costs reduced by approximately 45% compared to the original imported equipment. The DL2GPX continues to be selected for subsequent capacity expansions and has become the standard configuration for the mining area.
Technical parameters:
| Name |
Data |
Unit |
| Crushing roller specification |
1200×3000 |
mm |
| Spindle speed |
86 |
r/min |
| Feed opening size |
3080×2330 |
mm |
| Maximum feed size |
≤400 |
mm |
| Discharge size |
≤80 |
mm |
| Processing capacity |
~1000 |
t/h |
| Motor power |
220×2 |
kW |
| Overall dimension |
6979×3446×1420 |
mm |
Double Roller Crusher FAQ
Q1: Will the DL2GPX double-roll crusher experience material blockages when processing coal with high moisture content? Can the lump coal rate still be guaranteed?
A: The DL2GPX’s tooth rollers feature a self-cleaning tooth profile that prevents material adhesion; external adjustment allows adaptation to moisture content fluctuations. Field tests show that for coal with 10%–15% moisture content, the lump coal rate remains at 68%–72%, far outperforming traditional models under similar operating conditions. If moisture content remains consistently high, we recommend installing a pre-screening and dewatering system upstream.
Q2: How long do the crushing teeth on a double-roll crusher last? How long does it take to replace them?
A: A single set of crushing teeth is designed to handle over 3 million tons of material. Based on an hourly output of 800 tons, this equates to 7–8 months of operation. The tooth plates use a split, bolted-fastening design, allowing a single set to be replaced in just 8 hours—replace as needed without halting production.
Q3: For crushing calcium carbonate, is a double-roll crusher or a hammer crusher more suitable?
A: If the material is to be fed into a vertical mill or Raymond mill for fine grinding, with a required particle size of ≤30 mm and a need to minimize fine powder, choose the DL2GPX double-roll crusher—it offers high lump retention, minimal over-crushing, and uniform feeding. If the material is used directly as sand and gravel aggregate and the proportion of fine powder is not a concern, a hammer crusher offers lower investment costs. We can provide crushing test data to assist with decision-making.
Contact us now. Provide your material type, production capacity goals, and finished product requirements, and we will provide a detailed solution and a quote for the entire production line. For large-scale projects, we can arrange on-site visits and tours of similar production lines.
