What Specifications Enable Coal Crushers to Achieve 1200 TPH at 10 mm Output?
Tid:
21 May 2021
Achieving a throughput capacity of 1200 TPH (tons per hour) at a 10 mm output size for a coal crusher requires specific design considerations and engineering. Below are the key specifications and features that enable coal crushers to meet these parameters:
1. Crusher Type
- Double Roll Crushers or Impact Crushers: Double-roll crushers with roll diameters appropriately designed to crush coal at high capacities or specially designed impact crushers are often used. These crusher types offer high reduction ratios and can produce uniform output at smaller sizes like 10 mm.
2. Roll Diameter and Width
- Large Roll Diameter and Width: Double-roll crushers with larger roll diameters (e.g., 1000–1600 mm) and wider rolls (e.g., 600–1600 mm) can handle higher capacities. Larger surface areas on the rolls improve crushing efficiency and throughput.
3. Roll Peripheral Speed
- Adjustable Roll Speeds: A higher roll speed (but within the material’s fracture threshold) ensures the desired throughput while achieving fine granularity. Typical peripheral speeds range between 1.2 and 2.5 meters per second.
4. Crushing Teeth or Segments
- Adequate Tooth Design: For achieving small output sizes, specialized roll teeth, either staggered or in specific arrangements, break the coal effectively. The geometry of crushing teeth must be optimized to reduce large pieces into uniform particles of 10 mm or less.
5. Motor Power
- Sufficient Drive Power: Crushers must be equipped with adequately rated motors to provide the torque required for crushing at 1200 TPH. For large capacities and significant size reduction, motor sizes in the range of 200–600 kW or above are frequently used, depending on the crusher type and other factors.
6. Feed Size Management
- Feed Size Design: The crusher must be capable of handling maximum raw coal sizes being fed into the system (e.g., 1200 mm or larger). Pre-screening may be necessary to remove undersized particles and improve efficiency.
7. Reduction Ratio
- High Reduction Ratio Without Efficiency Loss: The crusher must achieve the required reduction ratio to convert large input material into 10 mm size while maintaining throughput. A reduction ratio of 8:1 or more may be required for some applications.
8. Advanced Hydraulic or Mechanical Adjustments
- Gap Adjustment Mechanism: An efficient gap adjustment system, such as hydraulic adjusters, ensures that the output size remains consistent at 10 mm despite wear on crushing elements.
9. Wear Resistance
- Durable Material Construction: The rolls or impact hammers, as well as liners, should be made from wear-resistant materials like manganese steel or tungsten carbide to handle continuous usage and abrasive coal surfaces.
10. Efficient Handling and Discharge Systems
- Discharge Capacity: A well-designed discharge mechanism ensures the crushed coal moves freely from the crusher without clogging, allowing the system to maintain the high throughput of 1200 TPH.
11. Supporting Infrastructure
- Robust Feeding System: Vibrating feeders or apron feeders to ensure a steady and uniform feed flow into the crusher.
- Proper Layout Design: Adequate space and arrangement to handle material loading, crushing, discharge, and secondary processes.
Key Considerations for Operation:
- Moisture and Coal Properties: Moisture content and the hardness (coal’s HGI — Hardgrove Grindability Index) will influence the crusher’s effectiveness. Proper selection of crusher type and settings should align with the specific coal properties.
- Dust Suppression Systems: Handling this volume of coal requires adequate dust control measures like water sprays or enclosures to comply with environmental regulations and improve operational safety.
By ensuring these specifications are adhered to, coal crushers can effectively deliver a throughput of 1200 TPH at a consistent output size of 10 mm. Continuous monitoring and maintenance are also critical for sustaining performance over time.
Contact Us
Shanghai Zenith Mineral Co., Ltd. is a leading manufacturer of crushing and grinding equipment in China. With more than 30 years of experience in the mining machinery industry, Zenith has built a strong reputation for delivering high-quality crushers, mills, sand-making machines, and mineral processing equipment to customers around the world.
Headquartered in Shanghai, China, Zenith integrates research, production, sales, and service, providing complete solutions for aggregates, mining, and mineral grinding industries. Its equipment is widely used in metallurgy, construction, chemical engineering, and environmental protection.
Committed to innovation and customer satisfaction, Shanghai Zenith continues to advance in intelligent manufacturing and green production, offering reliable equipment and comprehensive after-sales service to help clients achieve efficient and sustainable operations.
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