Coal Gangue Double Tooth Roll Crusher: Two Units Extract Sulfur Concentrate in Guizhou

A concentrator in Guizhou Province has long been recovering sulfur concentrate from coal gangue. However, the original crushing equipment suffered from frequent clogging, excessive fines, and poor liberation of pyrite, leading to low recovery rates and high operating costs.

Customer pain points

coal gangue double tooth roll crusher

The coal gangue comes from multiple mines with varying properties. High moisture and clay cause frequent clogging, while hard particles like pyrite and quartz cause rapid wear. Single‑stage crushing produces excessive fines, harming subsequent jigging and flotation and keeping sulfur concentrate recovery low.

HSM solution

After on‑site evaluation and material testing, HSM recommended two coal gangue double tooth roll crushers arranged in a two‑stage open circuit.

The first crusher performs coarse crushing. Large coal gangue enters the V‑shaped chamber and is broken to a medium size by low‑speed, high‑torque shearing action – not by impact. Because there is no screen plate and discharge is by gravity, clogging is eliminated even with wet material.

Coal gangue double tooth roll crusher production site

The second crusher performs fine crushing. The hydraulic system adjusts the roll gap to a smaller setting, further liberating pyrite from the gangue and producing a uniform product size. Both crushers use self‑cleaning tooth profiles and high‑chromium alloy hardfacing tooth plates, which offer long wear life against hard minerals like pyrite and quartz. A magnetic separator is installed between the two stages to remove tramp iron.

Results after commissioning

Clogging was completely eliminated. The gravity discharge and self‑cleaning teeth allowed continuous operation even during wet weather, dramatically reducing manual cleaning work.

Over‑crushing was significantly reduced. The low‑speed shearing produced far fewer fines than the original impact crusher. The product was uniform, blocky or cubical, creating excellent feed conditions for jigging and flotation.

Sulfur concentrate recovery increased noticeably. With similar feed grade, the concentrate grade became more stable and tailings sulfur content dropped. The customer reported that both recovery and concentrate quality met targets, bringing clear economic benefits.

The tooth profile of the coal gangue double tooth roll crusher can be customized according to the material.

Maintenance costs were well controlled. The high‑chromium hardfacing tooth plates lasted much longer under abrasive conditions, and the split design allowed individual tooth plate replacement without changing the whole roll. Spare parts inventory pressure decreased, and overall operating costs fell significantly.

Customer feedback

The production manager commented: “HSM’s two coal gangue double tooth roll crushers have truly enabled us to extract sulfur concentrate efficiently. The machines are stable, easy to maintain, and turn previously difficult gangue into valuable resources.”

Conclusion

For coal gangue containing pyrite nodules, a two‑stage double tooth roll crushing circuit is a proven approach. The HSM coal gangue double tooth roll crusher – with its low‑speed shearing, gravity discharge, hydraulic gap adjustment, and long‑life tooth plates – successfully solves the three major problems of clogging, over‑crushing, and rapid wear. It is a reliable solution for recovering sulfur concentrate from coal gangue.

Technical Specifications

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