Foreword

Welcome to value-conscious company. We are proud of the advanced engineering and

quality construction of each equipment we manufacture.
This manual explains the working of equipment. Please read it thoroughly and have all
the occupants follow the instructions carefully. Doing so will help you enjoy many years
of safe and trouble free operation.
When it comes to service remember that K.C. Engineers knows your equipment best
and is interested in your complete satisfaction. We will provide the quality maintenance
and any other assistance you may require.
All the information and specifications in this manual are current at the time of printing.
However, Because of K.C. Engineers policy of continual product improvement we
reserve the right to make changes at any time without notice.
Please note that this manual explains all about the equipment including options.
Therefore you may find some explanations for options not installed on your equipment.
You must follow the instructions and maintenance instructions given in the manual
carefully to avoid possible injury or damage. Proper maintenance will help ensure
maximum performance, greater reliability and longer life for the product.

K.C. Engineers

Contents
1.

Objective

2.

Aim

3.

Introduction

4.

Theory

5.

Description

6.

Utilities Required

7.

Experimental Procedure

8.

Observation & Calculation

9.

Nomenclature

10.

Precautions & Maintenance Instructions

11.

Troubleshooting

12.

References

Roll Crusher

ROLL CRUSHER
1.

OBJECTIVE:
To study the operation of Roll Crusher

2.

AIM:
To determine the efficiency of the Crusher for crushing a material of known Wi.

3.

INTRODUCTION:
Crushers are slow speed machines for coarse reduction of large quantities of solids.
The laboratory Roll Crusher is designed to crush ores, minerals, coal, coke, chemicals
and other similar material. It is compact and of rugged construction for general
laboratory or small pilot plant operations. Such crushers may contain two rolls,
smooth roll crushers and toothed roll crushers. Toothed roll crushers are much more
versatile than smooth roll crushers within the limitation that they cannot handle very
hard solids.

4.

THEORY:
Roll Crusher are used to reduce the particle size of materials to fine particles. They
are very common in industry and have a wide application. Crushing rolls consist of
two heavy cylinders revolving toward each other, the feed being nipped and pulled
downward through the rolls by friction. They rotate in opposite directions and the
clearance between them can be adjusted according to the size of feed and the required
size of product. Roll Crushers are classified as secondary crusher with feed 12mm to
75mm in size and products 12mm to 1mm. The forces exerted by the rolls can be
varied and adjusted by the springs provided. Crushing rolls are used for crushing oil
seeds and in the gunpowder industry and are also suitable for abrasive materials. They
are simple in construction and do not give a large percentage of fines.

BOND CRUSHING LAW AND WORK INDEX:

A more realistic method of estimating the power required for crushing and grinding is
Roll Crusher

P Kb
=
m
Dp

------------------ (1)

Where Kb is a constant which depends on the type of machine and on the material
being crushed, Dp is in millimeters, P in kilowatts and m in tons per hour.
Wi is defined as the gross energy requirements in kilo watt hours per ton of feed
needed to reduce a very large feed. This definition leads to a relation between Kb and
W i.

K b = 0.3162 Wi

--------------- (2)

If 80 percent of the feed passes a mesh size of Dpa mm and 80 percent of the product
a mesh of Dpb mm, it follows from eq (1) & (2).

1
P
1
= 0.3162 Wi

m
DPa
D Pb

1
1
P = m 0.3162 Wi

D
D Pa
Pb

5.

--------------- (3)

DESCRIPTION:
The Lab setup is used to crush different sample and material. Two heavy Smooth
faced chilled metal rolls turning on parallel horizontal axes are the working elements
of the roll crusher. A hopper is provided at the top for feeding the material. Particles
of feed caught between the rolls are broken in compression and drop out below. The
rolls turn towards each other at the same speed. They have relatively narrow faces and
are larger in diameter so that they can nip moderately large lumps. Loading bolts are
provided for safety. The maximum size of the product is approximately equal to gap
between the rolls & it can be adjusted by loading bolts.

6.

UTILITIES REQUIRED:
1. Electricity Supply: Single phase, 220 V AC, 50 Hz, 5-15 amp socket with earth
connection
2. Floor Area Required 1m x 1m.
3. Raw Material for Feed (size 5-8 mm)
4. Set of Sieves with Sieve Shaker for analysis.

Roll Crusher

7.

EXPERIMENTAL PROCEDURE:
1. Adjust the gap to produce the required product size.
2. Prepare a suitable feedstock of a solid material.
3. Measure its size distribution.
4. Check all the connections.
5. Start the machine with no load condition and record the time taken for 10-20
Pulses of energy meter for calculating power consumed by the empty machine.
6. Start feeding the solid material at a constant rate (m, Ton/h).
7. Again record the time taken for 10-20 Pulses of energy meter for calculating
power consumed by machine at loaded condition. Let it be PL.
8. Repeat the experiment for different product size.

8.

OBSERVATION & CALCULATION:

DATA:
EMC = 3200 Pulses/ kWh
Dpa

= ----------, mm

Dpb

= --------- , mm

Work Indexes for some common minerals

Material

Specific Gravity

Wi

BAUXITE

2.20

8.78

CEMENT CLINKER

3.15

13.45

COAL

1.40

13.00

COKE

1.31

15.13

GRAVEL

2.66

16.06

GYPSUM ROCK

2.69

6.73

LIME STONE

2.66

12.74

QUARTZ

2.65

13.57

OBSERVATION:
Wf = -------------, kg
tc = ------------, min
Roll Crusher

OBSERVATION TABLE:
Energy meter reading at no load condition
P

Energy meter reading at loaded condition

tp

tp

CALCULATIONS:
P NL =

P 3600
, kW = ------------------ kW
t p EMC

P 3600
, kW = ------------------ kW
t p EMC

PL=

P act = P L P NL , kW = ------------------ kW
1
1

P cal = m K b
, kW = ------------------ kW
D Pa
D Pb
K b = 0.3162 W i = ------------------

m=

9.

tc

60
, tons/h = ------------------ tons/h
1000

P act
100 %= ------------------ %
P cal

NOMENCLATURE:
Dpa

Average feed size, mm

Dpb

Average product size, mm

EMC =

Energy Meter Constant, Pulses/ kWh

Kb

Bonds constant.

Feed rate, Tons/ h.

No. of pulses.

PL

Power consume by machine at loaded condition, kW

PNL

Power consume by machine at no load condition, kW

Pact

Actual power required for crushing, kW

Pcal

Calculated power required for crushing, kW

tp

Time for P pulses, min

Roll Crusher

tc

Time for crushing, min.

Wi

Work index of material, kWh/ton

Wf

Weight of feed taken, kg

Crushing efficiency.

10. PRECAUTIONS & MAINTENANCE INSTRUCTIONS:

1. Never run the apparatus if power supply is less than 180 volts and above 230
volts.
2. The machine should not run when there is no oil in oil cups.
3. All the nuts and bolts of motor and unit fixed with the base are to be checked up
before operation.
4. Clean the Rolls and whole unit before and after its use with cloth.

11.

TROUBLESHOOTING:
1. If the feed material chokes in between the Rolls stopped the motor and remove the
choked material manually.
2. If the motor stops during experimentations and as you start but starter trips it
means starter over heated stop the crusher for at least 15 min and again start.

12.

REFERENCES:
1. McCabe, Smith Unit Operations of Chemical Engineering 7

th

ed, McGraw-

Hill, NY, 2005, Page 985-986, 988-989.

3. George Granger Brown, Unit Operations, 1st ed, CBS Publishers & Distributors,
ND, 1995, Page 34-36.

Roll Crusher