River pebble, calcite, quartzite, marble, pebble, bentonite, iron ore, bluestone, mountain stone, water slag, limestone, weathered sand, diabase, granite, basalt and so on

Feed size:25-100mm
Productive capacity:5-450t/h

Application:Highway, railway, high-rise buildings, municipal, hydropower dam construction, concrete mixing station, sand and stone field, etc.

Get Quote

Project Case Study

Maximizing Yield: How APEX Advanced Roller Crusher Transformed a 150-200 T/H Coal Plant

How Engineering Precision Eliminated Over-Crushing and Wet Material Clogging

Material
Raw Coal & Coal Gangue

Capacity
150 – 200 Tons / Hour

Output Size
Below 30 mm (Adjustable)

Equipment Model
APEX 2PGY1500×1200

The Challenge: High Waste Rates & Frequent Clogging

Our client, a large-scale coal preparation and chemical plant, was previously using a traditional hammer mill to process raw coal for thermal boiler feeding. However, they faced two critical bottlenecks that severely impacted profit margins:

Severe Over-Crushing: The high-speed impact action of the hammer mill generated over 25% coal powder (fines under 3mm), which burned away too quickly and caused massive economic loss.
Moisture Clogging: During the rainy season, raw coal moisture soared to over 12%, completely choking the crushing chamber and forcing shutdowns every few hours for manual cleaning.

Complete View of the APEX Coal Crushing Plant Site

The Solution: APEX 2PGY1500×1200 Large Hydraulic Roller Crusher

After diagnosing the material properties, our technical team configured the APEX 2PGY1500×1200 Fully Hydraulic Double Roller Crusher equipped with customized high-chromium alloy roller shells.

Unlike destructive impact crushing, the counter-rotating rollers utilize low-speed, high-torque static pressure extrusion. The raw coal is drawn smoothly between the rollers, crushed instantly along its natural geological fractures, and discharged cleanly via gravity.

Close-up of APEX 2PGY Roller Crusher Installation

The Results: 30% Energy Savings & Optimized Particle Size

Since commissioning, the plant has achieved stable 24/7 continuous operation with remarkable performance improvements:

✔ Fines Generation Dropped Below 5%
The over-crushing rate dropped from 25% to under 5%, significantly increasing the output value and profitability of high-premium sized coal.

✔ Zero Wet Material Clogging
Even during heavy rain and when processing 12%+ high-moisture coal, the continuous self-cleaning movement of the dual rollers completely prevented material sticking.

✔ 30% Direct Power Savings
The intelligent automatic hydraulic system drastically optimized electricity consumption, saving thousands of dollars in monthly utility bills.

Want to Achieve Similar Efficiency for Your Plant?

Contact our senior engineers for a free layout design and customized quotation based on your raw coal specs.

Get Expert Solutions

ONLINE MESSAGE

Let's talk, Send us a message today!

Our Cases

Successful Projects We've Completed

More Projects