With the experience gained by
manufacturing tailor-made machines
for the better part of 20 yr,
ThyssenKrupp has developed the next
generation of RollSizers, specially
designed to meet the requirements of
the coal industry. These machines were
combined to a modular system,
consisting of machines for primary,
secondary and tertiary crushing
stepped in several lengths to realise a
wide spectrum of capacities. This
enables the selection of a suitable
RollSizer directly from the catalogue
and thereby allows the basic
engineering of a crushing plant with
minimum delay. The concept of
standard machines not only
implements the modular system, it
also follows the idea of being close to
the regional markets. Using
prefabricated standard components,
which are assembled in local
manufacturing hubs, the delivery
time for standard RollSizers was
decreased significantly by eliminating
costly and time‑consuming
long‑distance transportation.
Modular system
RollSizers from the modular system
come in three varieties: the 1000 series,
the 800 series and the 660 series. The
numerical designations indicate the
centre-to-centre distances of their
rollers, as shown on Figure 2. The
660 series can be configured both as a
CenterSizer or a SideSizer, referring to
the crushing principle in the
machine. In a CenterSizer, the
material is crushed in the centre
between the two rollers, while in
SideSizers the material is forced
between the side walls of the housing
and the outside faces of the rollers.
Figure 3 shows the different crushing
principles used in RollSizers. The
crushing process in both types
implements a screening effect. Fine
material can pass the gap between the
rollers without being crushed, which
leads to a significant reduction of the
wear rate and improves the
power consumption.
Table 1 shows the complete product
range of standard RollSizers. The
designation of a RollSizer comprises
three parts: first, two numerical values
that represent the rolls’ centre-to-centre
spacing and overall length, respectively,
followed by a letter designation
indicating whether the machine is a
CenterSizer or a SideSizer.
Primary crushing
RollSizers DRS 1000 and DRS 800, which
are used for primary crushing, are
configured as CenterSizers. The big gap
between the rolls of these machines and
their special teeth arrangement enables
them to process feed sizes up to
1500 mm for the DRS 1000 series and
1200 mm for the DRS 800 series. By
equipping the machines with different
teeth arrangements, they can be adapted
to a multitude of applications,
depending on the properties of the
material and the demands on the
product. The teeth of the rolls are
outfitted with exchangeable crushing
picks to reduce the cost for wear parts
and decrease the downtime during
maintenance. All CenterSizers have
scraper bars in the housing, which
remove material buildup on the rollers,
enabling the machine to process sticky
or moist materials.
Additionally, the DRS 1000 can be
supplied with a breaker bar under the
gap between the rolls to increase the
reduction ratio. By vertical adjustment of
the breaker bar, the width of the
crushing gap and the size of the product
can be changed and optimised. The wear
parts were designed for a long life and
easy access. The breaker bar can be
Figure 4. Crushing tools of CenterSizer.
Table 1. RollSizer – standard machines for coal
CenterSizer
SideSizer
Primary RollSizer
Secondary/Tertiary RollSizer
Type
DRS 1000 x length
DRS 800 x length
DRS 660 x length
DRS 660 length
Roll distance
1000 mm
800 mm
660 mm
660 mm
Breaker bar
optional
no
no
no
Roll length (mm)/Rated
capacity (tph)
1500/1500
2250/2250
3000/3000
1500/900
2250/1350
3000/1800
1500/500
2250/750
3000/1000
1500/ 900
2250/1300
3000/1750
3700/2200
Minimum product size (mm)
0 – 300
0 – 250
0 – 120
0 – 30
All the above operation values are approximate and calculated under certain assumptions. The final data is determined on the basis of the specific
task.
46
|
World Coal
|
July 2015
