Coal Crusher Plant 80tph In Indonesia

Capacity:

80-100 ton / hour

Output size:

0-50mm

Material:

Coal

Configuration:

Dobule Roller Crusher 2PC900X1200, Vibrating Screen, Mobile Belt Conveyor System

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About Double Roller crusher for Coal Crushing 80t/h

Indonesia, as one of the world’s largest coal exporters, plays a vital role in global energy supply. The client from Indonesia faced significant inefficiencies in their coal processing workflow. This coal crusher plant is to optimize coal crushing operations that could process 80 tons of coal per hour while ensuring uniform particle sizes (0–50mm) suitable for power generation. This case study explores how the coal plant, equipped with core equipment like double roller crushers, vibrating screens, and mobile belt conveyors, addressed operational challenges and delivered exceptional results.

The Crushing Line Configuration & Equipment Introduction

To address these challenges, the plant was designed with a focus on mobility, efficiency, and durability. The core equipment included:

1. Double Roller Crusher (2PG 900×1200)

● Interlocking Teeth: The toothed rolls are excellent for breaking down large lumps of coal.

● Minimizes Fines: It produces a more uniform product with fewer ultra-fine particles compared to hammer crushers.

● Handles Moisture: The crushing action is less prone to clogging when processing coal with high surface moisture.

● Hydraulic gap adjustment allows real-time control of output size, adapting to client requirements.

2. Vibrating Screen

A heavy-duty Vibrating Screen is deployed after the roll crusher. Its primary function is to ensure product quality. It efficiently separates the crushed coal, allowing the correctly sized material (0-30mm) to pass through. Any oversized lumps are recirculated back to the roll crusher for further processing, creating a closed-circuit system that guarantees a consistent final product.

3. Mobile Belt Conveyors

● Function: Transporting coal between crushers, screens, and storage piles with flexibility.

● Advantages:

Mobile design allows easy relocation within the mining site, adapting to changing coal seams.

Adjustable height and length (up to 10m) optimize material flow and reduce manual handling.

Rainproof covers protect coal from moisture, preventing clumping and ensuring stable combustion

Key Advantages of Double Roller Crusher For Coal Crushing Process

1. Minimized Fines Production: The selective crushing action of the double roll crusher is the most significant advantage, preserving the value of the coal by reducing wasteful dust creation.

2. Low Operating Costs: With fewer moving parts and no high-speed rotors, the roll crusher offers exceptionally low wear costs and energy consumption per ton of coal processed.

3. Exceptional Flexibility and Mobility: The use of mobile conveyors and a modular design allows the entire plant to be relocated quickly, keeping operational costs low and efficiency high.

4. Simple Operation and Maintenance: The straightforward design of all components means less specialized training is required for personnel, and routine maintenance can be performed rapidly, maximizing uptime.

Baichy Machinery Service Support in Indonesia

Crushing Solutions Design

Baichy Machinery can customize a crushing plant for you based on the specific conditions of your project: such as the construction site, hardness of the raw materials, output, output size, budget, etc.

On-site Installation & Training

Our team provides on-site installation and thorough training to ensure safe operation of the crushing plant.

Quality Control & Global Delivery

Rigorous quality checks ensure compliance with standards, and we handle worldwide delivery to your location.

After-Sales Support

Baichy Machinery provides you with spare parts supply, project transformation, investment return analysis, etc.

Crushing Solutions Design

On-site Installation & Training

Quality Control & Global Delivery

After-Sales Support

Frequently Asked Questions (FAQs)

Find answers to the most common questions about Baichy Machinery. If you can’t find what you’re looking for here, please contact us.

1. Why choose a double-roll crusher over a hammer crusher for coal?

While both are effective, a double-roll crusher is often preferred for coal because it produces a more cubical product with a lower percentage of fines. It is also less sensitive to moisture and generally has lower wear costs, making it more economical for abrasive materials.

2. How is the final product size controlled in a roller crusher?

The product size is primarily determined by the gap between the two rollers. By adjusting this gap, operators can precisely control the maximum size of the crushed coal output. A smaller gap produces a finer product, while a larger gap produces a coarser product.

3. Why is a roller crusher preferred over a jaw or impact crusher for coal?

Coal is a relatively brittle material. Roller crushers utilize a compression method that breaks coal without the high-speed impact that creates excessive dust. They are also more energy-efficient, less prone to clogging from moist coal, and have lower wear parts costs, making them the most economical and practical choice for most coal crushing applications.

4. What is the expected lifespan of the roller crusher’s wear parts?

The manganese steel rollers have a service life of 3–4 months under continuous operation (8 hours/day, 6 days/week). Regular lubrication and maintenance can extend this to 5 months.

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