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

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.

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.

The Results: 30% Energy Savings & Optimized Particle Size

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

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