Hydraulic Roll Crusher

What is Hydraulic Roll Crusher?

A hydraulic roller crusher (also known as a hydraulic double-roll crusher) is a double-roll compression-type medium and fine crushing equipment. It is an energy-saving core equipment for medium and fine crushing in mining, sand and gravel plants, building materials, and solid waste treatment industries. It is primarily used for the compression crushing of high-hard to medium-hard materials, efficient sand making, uniform particle shape, and low over-crushing rate. Material falls from the top feed hopper between the two rollers and is subjected to high-pressure compression, shearing, and grinding, processing lumpy materials (≤120mm) into fine aggregate or manufactured sand (0.5–10mm). It is a key piece of equipment in the medium and fine crushing and sand making stages.

Key differences from cone crushers and impact crushers:

• Cone crusher: Medium and fine crushing of hard rock (granite, basalt), layered crushing, suitable for high hardness; cone crusher output particle size 5-50mm, double-roll crusher output <5mm.
• Impact crusher: Shapes soft rock (limestone) with high-speed impact, producing good particle shape but with rapid wear;
• Hydraulic roller crusher: Handles medium to low hardness, brittle, and sticky materials with low-speed, high-pressure extrusion, resulting in low powdering rate, low energy consumption, and wear resistance.

CHUNLEI Hydraulic Roll Crusher Advantages

• High-Strength Frame: Our hydraulic roll crushers utilize thick steel plate welded or integrated cast steel structures, ensuring durability, resistance to high-pressure impacts, and minimal deformation. They maintain stable operation even under high-intensity ore crushing conditions.
• High-Performance Crushing Rolls: Equipped with high-chromium alloy wear-resistant roller skin (Manganese 18Cr2) and alloy steel roller shafts, the roller surfaces can be selected as toothed or smooth, easily handling various ores and materials. High wear resistance reduces replacement frequency and lowers maintenance costs.
• Intelligent Hydraulic Adjustment: One-button adjustment of the roller gap and automatic overload protection. Actively avoids hard objects and automatically resets, improving production safety and efficiency, making operation easier and safer.
• High-Efficiency Transmission System: Motor + hardened tooth surface reducer + synchronous gears, dual rollers rotate synchronously at low speed, ensuring stable transmission, low noise, and energy efficiency, saving you electricity and operating costs.
• Sealed and Dustproof Design: Labyrinth seals and dustproof plates effectively prevent fine materials from entering the bearings, reducing dust accumulation, extending equipment life, and keeping the workshop clean.

Why Choose Our Hydraulic Roll Crusher?

• Stable and Durable: High-strength frame ensures worry-free long-term operation.
• Intelligent and Safe: Automatic hydraulic adjustment prevents material blockage and overload.
• High Efficiency and Energy Saving: Low-speed synchronous crushing reduces energy consumption.
• Easy Maintenance: Wear-resistant rollers and sealed design reduce maintenance costs.

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What are the differences between a hydraulic roller crusher and a conventional roller crusher?

Conventional roller crushers rely on springs and manual adjustment, resulting in weak protection and poor stability. Hydraulic roller crushers rely on intelligent hydraulic adjustment, offering strong protection, stability, durability, and high efficiency.

1. Adjustment Method

• Conventional roller crusher: Relies on springs and manual bolt adjustment, requiring machine shutdown, resulting in low precision and unstable output particle size.
• Hydraulic roller crusher: Fully hydraulic one-button adjustment, no machine shutdown required, high precision, uniform and stable particle size, improving production efficiency.

2. Overload Protection

• Conventional roller crusher: While spring buffering provides protection, it is prone to jamming or shaft breakage when encountering hard objects, affecting production capacity.
• Hydraulic roller crusher: The hydraulic accumulator automatically retracts and resets, preventing equipment damage, resulting in a low failure rate and allowing for 24-hour continuous operation.

3. Stability and Production Capacity

• Conventional roller crusher: Large pressure fluctuations and noticeable vibration, resulting in low and unstable production capacity.
• Hydraulic roller crusher: Constant pressure, smooth operation, high and stable production capacity, and higher production efficiency.

4. Maintenance and Costs

• Ordinary roller crusher: Inexpensive equipment, but wear parts wear out quickly, and labor maintenance costs are high.
• Hydraulic roller crusher: Slightly higher initial investment, but less wear, lower failure rate, and more cost-effective in the long run.

Working Principle: Low-Speed, High-Pressure Extrusion for Stable Fine Crushing

The hydraulic roller crusher employs a continuous cycle of “biting, extrusion, and discharge,” resulting in a stable, efficient, and uniform process.

When material enters the space between the rollers from the feed inlet, the rollers begin to rotate at low speed. The material is squeezed, sheared, and ground between the rollers, creating micro-cracks internally and gradually crushing it to the target particle size. The low speed (15–30 r/min) avoids impact wear, resulting in 12% lower energy consumption compared to an impact crusher. Fine particles (0.5–10 mm) fall through the roller gap and are discharged, while larger particles are carried to the top by the rotating rollers and re-enter the crushing chamber for circulation, ensuring uniform output.

What types of materials are suitable for processing?

Our hydraulic roller crusher is designed for efficient crushing of medium-hard materials, achieving uniform particle size, high stability, and low maintenance costs. It is ideal for mining, construction, and industrial applications.

Applicable materials:

• Minerals: Granite, basalt, limestone, calcite, coal gangue, iron ore, copper ore, and other medium-hard ores.
• Metallurgical and chemical materials: Talc, gypsum, refractory materials, bauxite, and various chemical raw materials.
• Building materials and aggregates: Sandstone, pebbles, crushed stone, bricks, slag, and other building aggregates.
• Special materials: Thanks to the intelligent hydraulic adjustment system, even high-moisture or slightly sticky materials can be easily handled, effectively preventing clogging.

What is the output of a hydraulic roller crusher (tons/hour)?

The output range of a single hydraulic roller crusher is 20–180 tons/hour, varying depending on the model, feed size, output fineness, and material hardness.

Small: 20–60 tons/hour, suitable for small sand and gravel plants and solid waste recycling lines;
Medium: 40–100 tons/hour, suitable for medium-sized aggregate production and construction waste processing;
Large: 80–180 tons/hour, suitable for large sand and gravel plants and cement clinker processing.

Key factors affecting output:

• Material hardness: Higher output for soft materials (limestone), slightly lower output for medium-hard materials (river pebbles);
• Output size: Finer output results in lower output; coarser particle size can increase output;
• Feed size: Oversized feed easily causes blockage and reduced output; the maximum feed size of the crusher must be matched to the model.

What are the feed and discharge particle sizes for a hydraulic roller crusher?

The maximum feed size for a hydraulic roller crusher is ≤50mm, with a typical stable feed size of ≤30mm; the discharge particle size is adjustable from 0.5 to 10mm, and can produce fine sand, medium sand, or small aggregates as needed.

• Maximum feed: 50mm (recommended ≤30mm to reduce material blockage)
• Standard output: 0.5–5mm fine sand, 5–10mm aggregate
• Adjustment accuracy: Hydraulic gap adjustment can reach ±0.5mm

Methods for controlling output and finished particle size

• Adjusting the roller gap (core): Increasing the roller gap in the hydraulic system → increases output, coarser particle size; decreasing the roller gap → decreases output, finer particle size; accuracy can reach ±0.5mm;
• Selecting roller surface type: Toothed rollers → high output, coarse particle size, strong material gripping; Smooth rollers → low output, fine particle size, good particle shape;
• Controlling the feed speed: Uniform and stable feeding, avoiding sudden changes in speed, preventing material blockage or idling, stabilizing output and particle size;
• Adjusting hydraulic pressure: Increase pressure for hard rock, decrease pressure for soft rock, balance crushing force and wear, extend roller life.

Can a hydraulic roller crusher perform both fine and medium crushing?

Yes, a hydraulic roller crusher can handle both medium and fine crushing in one machine, adapting to different production needs.

• Medium crushing mode: Increase the roller gap, output 5-10mm, high capacity, used for aggregate production;
• Fine crushing mode: Decrease the roller gap, output 0.5-5mm, used for manufactured sand production;

Hydraulic gap adjustment allows for flexible switching without changing parts, one machine covers both medium and fine crushing needs, offering high cost-effectiveness.

What are the advantages of hydraulic roller crushers compared to hammer crushers and jaw crushers?

Features	Hydraulic Roll Crusher	Hammer Crusher	Jaw Crusher
Output Particle Size	Uniform, stable and adjustable	Highly variable and inconsistent	Coarse output with significant fluctuation
Crushing Principle	Low-speed compression crushing	High-speed impact crushing	Compression crushing
Energy Consumption	Low	High	Medium to high
Continuous Operation	24-hour non-stop operation	Prone to wear, requiring frequent shutdowns	Prone to jamming, requiring frequent shutdowns
Overload Protection	Automatic hydraulic relief system	Weak spring/mechanical protection	Weak spring/mechanical protection
Maintenance Cost	Low, with long-lasting wear-resistant rolls	High, due to numerous wear parts	High, due to fast wear rates
Applicable Materials	Medium-hard to hard materials, including wet and sticky feed	Medium-soft materials; prone to clogging with wet feed	Large, hard lumps; primarily for coarse crushing
Key Advantages	Uniform gradation, energy efficiency, stable and safe operation	Low initial investment, suitable for medium-soft materials	Ideal for large hard rocks, simple structure

Need detailed parameters, customized solutions, on-site cases, or quotations for hydraulic roller crushers? Feel free to contact us anytime for free technical consultation, production line design, equipment selection advice, and one-on-one answers from our professional engineers!

Routine Maintenance Points

Maintenance focuses on inspection, servicing, and parts replacement to reduce malfunctions and extend lifespan:

• Daily Inspection: Check oil temperature, oil level, vibration, abnormal noise, and feed uniformity; clean debris from the feed inlet.
• Weekly Maintenance: Tighten external bolts; check roller wear and seal integrity.
• Monthly Maintenance: Lubricate bearings; calibrate roller gap; clean accumulated material from the crushing chamber; check hydraulic system pressure.
• Regular Parts Replacement: Replace rollers (8–24 months), seals (6–12 months), and bearings (2–3 years). Genuine parts are readily available for replacement.
• Long-Term Protection: Prevent hard objects from entering the chamber; avoid overloading; protect the hydraulic system and extend the overall machine lifespan.

Technical Parameters of Hydraulic Roll Crusher

Model	Roller Skin Diameter (mm)	Roller Skin Width (mm)	Maximum Feed Particle Size (mm)	Discharge Port Corresponding Theory Processing Capacity (t/h)			Motor Power (kw)
				5mm	10mm	20mm
2PGY0604	ø 600	400	≤30	8-10	10-15	10-20	2×15
2PGY0806	ø 800	600	≤40	15-20	18-35	25-50	2×30
2PGY1008	ø 1000	800	≤40	8-33	24-98	32-130	2×55
2PGY1210	ø 1200	1000	≤60	12-50	37-148	49-197	2×90
2PGY1510	ø 1500	1000	≤80	15-60	46-185	60-245	2×160
2PGY1810	ø 1800	1000	≤100	18-75	55-220	73-295	2×250
2PGY2012	ø 2000	1200	≤120	25-100	73-295	97-390	2×315

FAQ

Q: Can a hydraulic roller crusher be used with a mobile crushing plant?

A: Absolutely. Customized tracked/wheeled mobile roller crushers are available, integrating feeding, screening, and conveying. They offer flexible relocation, require no infrastructure, and are suitable for demolition sites and scattered outdoor mines.

Q: Can it be used in a production line with a cone crusher/impact crusher?

A: Yes, classic combinations include:
● Hard rock: Jaw crusher for coarse crushing + Cone crusher for medium and fine crushing + Roller crusher for sand making;
● Soft rock: Jaw crusher for coarse crushing + Roller crusher for medium and fine crushing + Impact crusher for shaping; balancing particle shape, capacity, and cost.

Q: What auxiliary equipment is required?

A: Basic configuration: Feeder, conveyor belt, vibrating screen, magnetic separator, hydraulic oil station; enclosed production lines can be equipped with dust removal equipment to reduce dust pollution.

Q: What is the lifespan of wearing parts? Are they easy to procure?

A: The main wear parts are roller skin and seals: roller skin lasts 15-24 months in soft rock conditions and 8-12 months in medium-hard rock conditions; original parts are universal, easy to replace, and readily available in the market.

Q: Are there any requirements for power supply and site conditions?

A: Industrial power supply is required; a flat and hardened site is sufficient; large models have reserved maintenance space; mobile models have no infrastructure requirements and are highly adaptable.