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A coal crusher is a special type machine that is used to crush large block of raw coal into small and uniform particles. Coal crushers are widely used in mining, power generation, cement and steel industries, as well as some other industrial applications. There are several types of coal crushers in the market.
Hammer mill coal crusher:
This crusher uses a high-speed rotor with a thick, reinforced hammer to crush and grind the raw coal. The hammer uses centrifugal force to impact, cut or slice the coal into smaller pieces. The granulation of this type of coal crusher is usually between 5 and 25 mm. It can crush both wet and dry coal.
Roller crusher:
This coal crusher uses two parallel rotating rollers to crush coal into smaller pieces. The raw coal is fed between the two rollers, which squeeze, break and fracture the coal into smaller granules. The final size of coal granules from roller crushers are usually between 10 and 50 mm. This type of coal crusher is suitable for handling larger volumes of coal.
Impact coal crusher:
This type of coal crush works by using the force of impact to break the coal. An electric motor drives the rotor of the impactor at high speed. Raw coal will then be thrown into the impact plates by the high-speed hammer head. The coal is subsequently crushed and shaped into smaller pieces when it touches the impact plates. The impact coal crusher is generally used for moist and muddy coal.
Primary coal crusher:
This type of coal crush is usually installed at the mine site to process freshly mined coal. It can reduce the 1 meter sized coal into a more manageable size for further processing at the coal plant. Depending on the design, a primary coal crusher may be a hammer crusher, rotary crusher or jaw crusher.
Secondary coal crusher:
This type of coal crusher usually takes the primary crushed coal as input. It further processes the raw coal to produce smaller granules. The coal granules produced by secondary coal crushers are sent to the power plant, cement factory or steel mill for production.
Feed Size:
It is the maximum size of raw coal that a crusher can accept for processing. Depending on the machine, the feed size can differ. For instance, the specialized crushers can handle larger pieces with a feed size of about 300 to 800 mm. However, the primary crushers like jaw crushers and gyratory crushers typically have a larger feed size.
Output Size:
The output size refers to the amount of coal the crusher produces after processing the raw coal. The output size may vary according to the type of coal crusher being used. For instance, a jaw crusher may give output sizes ranging from 20 to 80 mm, while a roller crusher may give output sizes of 0 to 20 mm.
Capacity:
The capacity of the coal crusher refers to the amount of coal it can process in a given time, usually measured in tonnes per hour (TPH). Different types of coal crushers have varying capacities. For example, a small-scale hammer crusher may have a capacity of 5 to 20 TPH, whereas an industrial-scale impactor may achieve 100 to 200 TPH. In general, the larger and more powerful the crusher motor, the higher its capacity.
Motor Power:
The motor power of a coal crusher indicates the power needed to crush the coal. This is usually measured in kilowatts (kW) or horsepower (HP). The motor power varies by the type and size of the coal crusher. A small coal crusher may have motor power of 5.5 kW, while a larger one may have 75 kW or more.
Inspection:
Users should regularly inspect the machine parts, such as the hoppers, feeding belts, crushers, discharging belts, bearings, pulleys, transmission chains, and other components, to look for noticeable signs of wear or damage. They should replace or repair the damaged parts as needed to ensure the proper function and safety of the coal crusher.
Lubrication:
The bearings, transmission chains, and belts of the coal crushers should be lubricated regularly to guarantee smooth operations. It helps to decrease the impact forces that the crushers experience, reducing the wear and tear on the equipment, thereby extending the service life of the coal crusher.
Clean-up:
Users should remove the leftover coal dust and debris after operating the crushers to avoid coal blockages. Coal dust is a common foe of coal crushers, notorious for damaging electrical components and motors, leading to various equipment failures. Therefore, frequent cleaning would help avoid damage and maintain a normal operation.
Replacement:
Users must replace the easily worn-out parts, such as hammers, impact plates, and blades, according to the usage frequency and conditions to maintain a good crushing effect and efficiency.
As the name suggests, coal crushers break down large pieces of coal into smaller, usable pieces. Smaller coal pieces make it easier to transport and burn in thermodynamic power plants to produce electricity. To this end, coal crushers are vital for the power generation and mining industries.
For reference, approximately 37% of the world's electricity is produced by coal power plants.
Aside from preparing coal for use in power generation, crushers are also used for other types of rock and mineral-based fuel to produce smaller pieces suitable for burning. This makes crushers equally vital to other industries looking to create smaller pieces of any type of hard material.
Some of the industries that use crushers include the following:
Construction
Coal crushers are essential in the construction industry. They break down large boulders of granite, marbles, and limestone to produce smaller pieces that are used in the creation of asphalt and concrete.
Landscaping
Coal crushers are also used in the landscaping industry when large pieces of decorative rock or gravel need to be broken down to make commuting paths or drainage systems.
Tennis Courts, Golf Courses, and Football Fields
Sports industries may also use coal crushers to produce smaller gravel or rock pieces that improve drainage on golf courses and tennis courts. This prevents standing water on playing surfaces and helps provide a better sports experience.
Road Works
Road work projects may also use coal crushers to produce smaller pieces of rock that can be used for the top layer of roads. The durability of crushed granite or marble is well-documented. Road work projects may also use crushers to produce smaller pieces of rock that can be used to improve the tensile strength of asphalt.
There are a few things business buyers should consider before investing in a coal crusher for their businesses.
Required capacity
Before buying a crusher, buyers should evaluate the amount of coal their production processes need. Larger mining operations typically need crushers that can handle over 1000 tons of coal per hour. Smaller operations may only need to crush 20 to 100 tons of coal per hour. An easy way to know the required capacity is to consider the amount of coal used to run the end processes.
Percentage of fine coal needed
In some industries, moving coal fines is quite important. Businesses buyers should determine the amount of fine coal needed in the end markets. If there is a substantial need for fine coal, it may be ideal to invest in crushers with the ability to produce coal fines instead of just large coal chunks.
Types of coal on-site
There are different coal types, from lignite to anthracite, with distinct compositions and crushing requirements. Buyers should evaluate the type of coal they are working with and ensure that the selected crusher is suitable for it. For example, rotary crushers are ideal for lignite and sub-bittuminous coal, while hammer crushers are perfect for bituminous and anthracite coal.
The need for air pollution control
In mining operations, there is a great need to control air pollution. This has led many to invest in coal crushers with air pollution control systems. Business buyers should know that such systems can increase a machine's cost. So, it is better to evaluate the requirement for air pollution control at the business site and then determine the type of system to choose.
Regular maintenance requirement
It is essential to choose a coal crusher that is easy to maintain. Regular maintenance required for these machines can lead to operational downtime. Some coal crushers require more maintenance than others. Learn about the maintenance requirements of the machine to be chosen and ensure spare parts availability.
Automation and control systems
Some modern coal crushers have advanced automation and control systems for remote monitoring, integrated coal feeding systems, and automated re-setting capabilities.
Business buyers can improve their operational efficiency by streamlining the integration process and ensuring that the coal crusher is easily controllable and auto-manageable. Look for coal crushers with user-friendly interfaces and automated features that can integrate seamlessly with existing production lines.
Q1: How does a coal crusher work?
A1: A coal crusher works by using mechanical force, impact, and compression to break down large chunks of coal into smaller, manageable pieces. It feeds the coal into the crushing chamber, where it is struck by hammers. The shattered coal is then pushed downwards and further crushed by the rollers until it reaches the desired output size.
Q2: What are the types of coal crushers?
A2: There are many types of coal crushers, but the most common ones are the ring granulator, the hammer mill, and the roller crusher. The different types of coal crushers are suitable for varied applications and have their unique advantages and efficiencies.
Q3: How important is a coal crusher in coal handling?
A3: A coal crusher is an important component in the coal handling process. It ensures the proper size reduction of coal to meet specific requirements for combustion and other industrial processes. By maintaining flow and preventing blockages, coal crushers support overall efficiency, smooth operation, and the effective management of coal supplies.
Q4: Are coal crushers used only for coal?
A4: No. Coal crushers are not used only for coal. They are also used to crush other materials like charcoal, sodalite, slate, gunpowder, feldspar, aggregates, sandstone, marble, ores, limestone, etc., that require size reduction for processing, handling, or specific applications.
