Double roll crusher
Aston Double Roll Crusher: Precision Reduction & Minimal Fines Generation
Engineered for exceptional secondary and fine crushing, the double roll crusher efficiently processes medium-hard minerals and brittle bulk feed under 80 mm down to a uniform 50 mm–20 mm finish. Delivering stable performance across diverse operations, it serves as a core solution for manufactured sand, ceramic raw materials, mineral processing, and industrial material reduction in cement, metallurgy, and power sectors.
Built with counter-rotating heavy-duty manganese alloy rollers and an adjustable discharge gap, this machine provides precise control over particle gradation while minimizing dust and over-grinding. Its rugged drive mechanism handles tough feeds smoothly—such as river pebbles, iron ore, quartz, and coal—maintaining continuous throughput with exceptional operational stability.
Featuring a streamlined mechanical layout and wear-resistant roll surfaces, the double roll crusher significantly reduces power consumption per ton and simplifies routine maintenance. Its low operating costs and high wear longevity make it a cost-effective, long-term asset for small-to-medium processing facilities and complete production lines.
Feed specifications & Finished aggregate output
Feeding size: ≤110mm
Finished products size: 2~8mm
Capacity: ≤240t/h
Coarse stone
Middle size stone
Fine stone
Application field of double roll crusher
Material
Highly effective for processing a wide range of medium-hard and brittle rocks and minerals—such as river pebbles, iron ore, quartz, limestone, clinker, slag, coke, coal, shale, and ceramic raw materials. Designed to handle both dry and sticky or moderately moist feeds, it delivers predictable size reduction with minimal over-crushing and exceptionally low dust generation.
Application
Widely utilized in manufactured sand production, mineral dressing, ceramics, refractories, cement plants, chemical processing, metallurgy, and power generation. It provides a reliable, low-energy secondary or fine crushing solution for facilities seeking tight particle control, low operating costs, and streamlined material handling circuits.
Double roll crusher features:
- Compact & Lightweight structure: Direct-coupled motor drive and optimized frame geometry reduce overall machine weight and equipment height, allowing effortless integration into limited spaces or mobile platforms without sacrificing structural rigidity.
- Minimal footprint & Simplified maintenance: The side-by-side dual-roll layout minimizes installation footprint, while hinged inspection doors and modular bearing housings enable rapid access for gap adjustment and roll shell replacement.
- Advanced dust sealing & Low-noise operation: Internal labyrinth seals combined with heavy-duty rubber dust curtains fully enclose the crushing chamber, blocking airborne particles at the source and dampening impact vibrations to achieve clean, low-noise operation.
Specification of double roll crusher:
| Model | Roller diameter (mm) | Roller width (mm) | Feeding size (mm) | Discharging size (mm) | Capacity (t/h) | Motor power (kw) |
| 2PG400x250 | 400 | 250 | <35 | 2-8 | 2-10 | 5.5×2 |
| 2PG400x400 | 400 | 400 | <35 | 2-8 | 5-15 | 7.5×2 |
| 2PG610x400 | 600 | 400 | <40 | 2-8 | 10-20 | 15×2 |
| 2PG750x500 | 750 | 500 | <40 | 2-8 | 15-30 | 18.5×2 |
| 2PG800x600 | 800 | 600 | <40 | 2-8 | 25-40 | 22×2 |
| 2PGY1000x700 | 1000 | 700 | <60 | 2-8 | 35-60 | 30×2 |
| 2PGY1200x800 | 1200 | 800 | <60 | 2-8 | 50-100 | 45×2 |
| 2PGY1500x800 | 1500 | 800 | <80 | 2-8 | 90-140 | 90×2 |
| 2PGY1500x1000 | 1500 | 1000 | <80 | 2-8 | 120-180 | 110×2 |
| 2PGY1800x1000 | 1800 | 1000 | <100 | 2-8 | 160-240 | 160×2 |
Materials processed by double roll crusher
Dolomite
Bentonite
Limestone
Coal
Gypsum
Bricks & Tiles
Recycled concrete
Coal gangue
Phosphate rock
Rock salt
Talc
Shale
Versatile applications for double roll crusher
Double roll crushers deliver stable, controlled size reduction in medium and fine crushing stages. Operating via high-pressure roll squeezing and shearing, the equipment effectively processes brittle, medium-hard, and friable materials down to strict particle limits—minimizing over-grinding, lowering energy consumption, and replacing energy-intensive secondary milling units.
Typical application areas
Manufactured sand & Aggregate processing:
The machine crushes hard-to-fine rocks—such as river pebbles, quartz, and limestone—into high-quality cubical sand with controlled fine content, providing ideal fine aggregates for concrete batching and asphalt mixing plants.
Mining & Mineral beneficiation:
Designed for fine crushing of iron ore, metallic minerals, and gangue, the precise roll gap control ensures narrow output particle size distributions, optimizing feed quality for downstream grinding mills and magnetic separators.
Metallurgy, chemical & coal industries:
It handles brittle bulk feeds like coke, coal, slag, and industrial clinker. The gentle compression action prevents excessive fines and dust generation, ensuring optimal permeability for blast furnace smelting and chemical gasification.
Ceramics & Refractory manufacturing:
It reduces raw clays, feldspar, and refractory minerals down to fine, uniform grains without thermal degradation or excessive wear, streamlining raw material preparation for kiln firing and molding circuits.
Explore industrial applicationsWorking process of double roll crusher
The double roll crusher operates through continuous, high-pressure roll squeezing and attrition shearing. Utilizing dual independent motor drives and heavy-duty gear transmissions, two counter-rotating manganese steel rollers draw incoming bulk material into the crushing nip, executing precise size reduction down to exact particle specifications.
Bulk raw material enters the upper hopper continuously via a regulated feeder. The intake design ensures even material distribution across the full length of the roll face, preventing localized roll wear and setting up ideal conditions for uniform nipping.
Power is delivered by two separate electric motors. One motor drives the fixed-bearing roller via V-belt transmission; a heavy-duty side gear mounted on the fixed roller shaft then meshes directly to drive the movable-bearing roller, achieving synchronized counter-rotation at optimal operating speeds.
Driven by huge kinetic energy and gravity, shattered fragments are hurled against the wear-resistant breaker plates and frame liners. The rebounding material is bounced back into the path of the rotating hammers, undergoing repeated impact, collision, and friction until the grain size is significantly reduced.
The bottom of the crushing chamber is equipped with an adjustable grate/sieve plate. Material reduced below the screen gap passes through immediately for discharge. Oversized particles are retained on the grate, receiving continuous hammering and attrition from the hammer tips until they reach the target size to pass through.
Double roll crusher main components
Engineered for efficient compression crushing, our double roll crusher utilizes opposing roller pressure to deliver controlled reduction with minimal over-crushing and high cubicle yields. Built with heavy-duty drive components, wear-resistant alloy surfaces, and automatic overload protection, it ensures stable throughput and low operational costs even when handling sticky, wet, or friable materials.
The grinding rolls feature structurally optimized bodies equipped with replaceable wear-resistant alloy liners. Engineered to withstand high surface friction and heavy compression, this design ensures long operational service life and hassle-free liner replacement.
High-capacity spherical roller bearings support the counter-rotating shafts, seamlessly accommodating heavy radial loads. The sealed bearing seats maintain dynamic shaft balance and smooth rotation during continuous heavy-duty crushing operations.
Equipped with a flexible pressing and gap-setting mechanism, this assembly maintains optimal grinding pressure between the rollers while enabling precise control over product sizing to suit diverse application requirements.
The internal crushing chamber is lined with dust-resistant plates within a tight protective enclosure. This effective seal prevents fine material splashing, drastically reduces dust emissions, and lowers operating noise levels on-site.
An integrated safety protection mechanism automatically triggers when uncrushable metal debris enters the chamber. The floating roll retracts momentarily to discharge foreign objects safely before automatically resetting to resume normal production.
