Advanced Mineral Processing Solution

Double Tooth Roll Crusher for Wet & Sticky Ores

An integrated low-speed, high-torque approach to crushing wet, sticky materials, cutting downtime, and guaranteeing continuous production.

In coal preparation, bauxite mining, and construction waste recycling, plant operators face a persistent enemy: material adhesion. When conventional jaw, impact, or cone crushers process high‑moisture feed (coal gangue, clay‑rich bauxite, or wet asphalt millings), fine particles quickly coat the crushing chamber and screen openings. This buildup triggers progressive clogging, motor current spikes, and unscheduled shutdowns for manual cleaning. Beyond lost production hours, the high‑speed impact action generates excessive fines (<6 mm), which impair downstream jigging or heavy‑media separation and increase tailings disposal costs.

2. The Integrated Technology Blueprint

Our Double Tooth Roll Crusher replaces chaotic impact with controlled, low‑speed shearing. The system is engineered to continuously clear itself while delivering a cubical, low‑fines product:

• Self‑Cleaning Tooth Geometry – Specially spaced, high‑strength teeth tear and shear the material instead of compressing it against solid surfaces. Wet fines fall away naturally, keeping the crushing cavity open even at 30 % moisture. No more “bridging” or “blind‑hole” buildup.

• Low‑Speed, High‑Torque Drive – Twin motors and reducers operate at 50–90 RPM, generating massive torque without impact shock. This consumes 15–25 % less energy per tonne than impact crushers and eliminates the production of micro‑fines. The resulting -6 mm fine fraction stays below 15 %, preserving particle strength for downstream separation.

• Segmented, Long‑Life Roll Discs – Each roll is assembled from individual, replaceable disc segments made of high‑chromium manganese alloy. Worn discs can be changed on site without lifting the entire roll assembly, cutting maintenance downtime by up to 70 %. Optional hardfaced or carbide‑studded surfaces extend wear life even further.

• Hydraulic Overload Protection – When an uncrushable object (tramp iron, rock bolt, hard boulder) enters the crushing zone, the hydraulic system instantly widens the roll gap, lets the object pass, and resets automatically. No roll breakage, no gearbox damage, zero unplanned stoppages.

The result is a rugged, high‑availability crusher that keeps sticky, wet materials flowing – maximizing throughput while minimizing fines and cleaning interruptions. Operators gain lower energy bills, longer wear part life, and a product that meets the strict particle size requirements of modern coal washing, bauxite beneficiation, or landfill diversion projects.

Request a Custom Circuit Blueprint

Send your crude ore hardness metrics (Mohs scale), raw moisture parameters, and target grading sheets to our application engineering team for an advanced layout calculation.