The Problem: Severe Clogging & Low Sulfur Recovery Due to Over‑Crushing

A large coal preparation plant had long been using a hammer crusher to process high‑moisture coal gangue (25%–30% moisture). Due to the high clay content of the gangue, material quickly adhered to the crushing chamber grate bars and screen plates, forcing 1–2 cleaning shutdowns per shift and reducing plant availability to below 65%. Meanwhile, the high‑speed impact action of the hammer crusher generated over 30% of fines below 6 mm. Pyrite was excessively pulverized into micro‑fines, which could not be effectively recovered by downstream jigging or flotation, resulting in low pyrite concentrate yield and significant sulfur loss to tailings.

150 T/H Coal Gangue Crushing & Sulfur Recovery Plant Upgrade

The Solution: Double Tooth Roll Crusher Integration

The plant replaced its hammer crusher with our heavy‑duty Double Tooth Roll Crusher. Operating at a low speed (≈70 RPM) with high torque and differential roll rotation, the crusher tears and shears the coal gangue rather than impacting it. The self‑cleaning tooth geometry allows wet fines to fall away naturally, keeping the crushing cavity clear even at 30% moisture – no clogging. At the same time, the shear‑dominated action keeps -6 mm fine powder below 15%, preserving the integrity of pyrite particles and significantly improving downstream jigging and flotation recovery. After commissioning, the equipment runs continuously without manual cleaning, and the pyrite concentrate yield has increased by more than 40%.