CHE1022: Mechanical Operation Lab

Expt No :6
Date :

ROLL CRUSHER
AIM:

To find the power consumption, reduction ratio, angle of nip and the theoretical
capacity of the roll crusher operating on a given speed.

APPARATUS:

Roll crusher setup, Feed sample, Sieves, Sieves Shaker, Stop - Watch and the
Balance.

THEORY:

Two heavy smooth rolls turning on parallel horizontal axis are the working elements
of the roll crusher. Particles of the feed caught between the rolls are broken and dropped
below. Smooth roll crusher are used as secondary crusher with feed ½ “ to 3” in size and the
product size ½” to 20 mesh. To allow unbreakable material to pass through without damaging
the machine at least one roll must be spring mounted. The roll turns towards each other at the
same speed. They have relatively narrow faces and are large in diameter so that they can nip
moderately. The particle size of the product depends upon the gap between the rolls and the
clearance capacity of the given machine. The angle of the nip is angle between the roll faces
at a level where they take hold of the particle and take it to the crushing zone.

PROCEDURE:

Take about 1kg of the feed material and weight it. The Average particle size is
determined by finding out the volume of around 10 – 15 particles. Switch on the starter, to
start the roll crusher. Feed the material in the crusher slowly and note the total time for
crushing. Record the time taken for 10 impulses in the energy meter under load and unload
conditions.
From the crusher product is collected at the bottom of the crusher. From the product
the sample is collected using coning and quartering sampling technique. The sample is fed
on to the top sieve of a set of sieves arranged. Close the top sieves with lid and place it on a
CHE1022: Mechanical Operation Lab

sieve shaker. The sieving is completed for duration of 15 minutes. After sieving weigh the
sample material retained on each mesh separately and record.

OBSERVATIONS:

Feed Size DF = m
Diameter of rolls D = m
Width of Rolls B = m
Clearance between the rolls = 2d = m
Speed of roll N = rpm
Specific gravity of material S =
Energy meter Constant k = Imp / Kwh
Time taken of N impulses
Under no load – to = sec
Under load – t1 = sec
Time of Crushing t = sec.
Weight of Solid taken, w = kg.

CALCULATIONS:

Dai of the feed DF = 2r =

𝑁∗ 𝑒∗ 3600
Power consumed on no Load Condition (P0) = KW
𝑡0

𝑁∗ 𝑒∗ 3600
Power consumed on Load Condition (P1) = KW
𝑡1

Power required for crushing P1 – P0 =

𝑊
Actual capacity of crusher = = tons/ hr
1000∗𝑡∗3600

Theoretical capacity of crusher = 60 ∗ (2𝑑 ) ∗ 𝜋𝑁𝐷 ∗ 𝑏 = m3/hr

Where q= volumetric capacity in m3/hr

d=one half of the roll spacing, m
N= speed of rolls in rpm
D=Diameter of the rolls, m
CHE1022: Mechanical Operation Lab

Hence theoretical capacity in tonnes/hr = qρs =tonnes /hr

PRODUCT SIZE:

1
____________
By differential analysis =
 xi / Dp

1
By cumulative analysis =
d
1

0 Dp
REDUCTION RATIO (RR):

Feed Size =
RR by Differential analysis = D f/Dp
RR by Cumulative analysis =D f / Dp

Calculation of Angle of nip

𝑟+𝑑
𝑐𝑜𝑠𝛼 =
𝑟+𝑅
Angle of nip =2=

GRAPH:
Draw graph between  Vs 1/Dp
CHE1022: Mechanical Operation Lab

Tabulation:

Cut Dia Avg. Dia Weight Weight Cumulative 𝑥𝑖

Sl. No Mesh Dpi ̅̅̅̅̅̅
(𝐷 𝑝𝑖 )
retained Fraction Weight ̅̅̅̅
𝐷
Number (mm) gm xi Fraction 𝑝𝑖
mm (mm-1)


RESULT:

1. Power required for Crushing:

2. Theoretical Capacity:
3. Actual Capacity:
4. Angle of Nip:
5. RR by Differential analysis :
6. RR by Cumulative analysis :