02 - Double Roll Crusher

PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology

Chemical Engineering Department
DOUBLE ROLL CRUSHER
DESIGN PROBLEM
Design an equipment that would reduce the size of the incoming 1,340 kg of
alimasag shell to a particle size within the range of 1-10mm.
DESIGN DESCRIPTION
Compression crushing is a process where raw materials are crushed to a particle

size using the gap between the rollers. A double roll crusher is a compression type size
crusher for materials up to 8th degree of the Mohr’s scale of hardness such as ceramic
material, shell raw materials, slag, clinker, quartz sand, lime, limestone, bentonite, scrap
glass, etc. The 1,340 kg of alimasag shell will be compressed to a particle size within the
range of 1-10mm after it passes through the gap between two large rolls. Product size is
determined by the size of the gap between the rolls, and this gap can be changed to
vary product size
The 1,340 kg of alimasag shell is taken from a hopper positioned in the upper part
of the mill to the main grinding roller. On entering the slot, the material is evenly
distributed across the adjacent driving rollers. The rotary movement of other two driving
rollers is initiated by friction of the material ground between the two smooth rollers.
These two smooth rollers, circulated using V-belt drive motor, rotate toward each other
and the 1,340 kg of alimasag shell is grabbed, compressed and pulled down into the
crushing zone going to the discharging hopper. The discharging hopper is situated at
the lower part of the equipment were a screw conveyor is attached to transport the
ground alimasag shell to the ball mill.
DESIGN SELECTION
The double roll crusher is selected because in this batch process, alimasag shell
will be reduced to 1-10 mm after the size reduction. Since the alimasag shells must be
size reduced first, ball mill is also not feasible since it grinds the material to particle sizes
smaller than 20 Mesh which is not the aim of the design. The ball mill will act as the
secondary crusher for our alimasag shell. Moreover, the feed for ball mill must be 1 to 10
mm only (Couper et. al.). Thus, another type of mill must be used.
Based from Unit operations of Chemical Engineering by McCabe, smooth-roll

crushers can produce a product 1 to 10 mm in size. Also, the feed size available ranges
from 12 to 75 mm where alimasag shells are within this range. The reduction ratios of 40
are feasible. This reduction ratio is in line with the requirements of our design.
Plasticization of Chitosan from Alimasag Shells and Cellulose Nanocrystal from Tobacco Stalks for
Technical
the Production of Liner Film 23
R.C.Macasil, M.D.Mendoza, K.J.O.Raymundo, D.J.S.Saya Study
Figure : Different size reduction equipment (General Design and Sizing of Comminution
Equipment by Metso, Inc.)
Figure shows several equipment within their corresponding feed particle size. For
cone crusher and jaw crusher, the particle size ranges from 1m to 10 mm. For horizontal
and vertical roller crusher, the size ranges from 10mm to 1 mm. For rotary grinders, the
particle size ranges from 10 micron to 1 micron. Therefore, double roll crusher is selected
based on the particle size.
DESIGN PARTS AND ACCESSORIES
Figure 9.27 Parts of the Double Roll Mill
Table 9.29 Parts and Functions of the Double Roll Mill

Parts Function
This is where the alimasag shell is evenly distributed to
Feed Input Hopper
the roll mill
Technical
This is where the size reduced alimasag be discharged.

Product Hopper
This is also where the screw conveyor be attached
Motors This is the source of grinding power.
V-Belt Drive It transmit the power of the motor
Double Rolls This is the grinding media.

This will enclose the alimasag shell and this will serve as a
Exterior/Cover
protecting part of the equipment
This will secure the two rolls and this will prevent damage
Spring to the equipment by absorbing the vibration and erratic
enlargement of gap between rolls
DATA AND ASSUMPTIONS
1. The mass of incoming alimasag shells from the belt conveyor is 1,340 kg. (Based
on Material Balance)
2. The alimasag average width is 20 mm. (Based on Experiment)
3. The bulk density of alimasag shells is 567.9 kg/m3. (Based on the Experiment)
4. The exiting particle size is 10 mm.
(http://www.mineengineer.com/mining/rollcrush.htm)
5. The time of crushing the alimasag shells is 10 min.
DESIGN CONSIDERATIONS
1. A safety factor of 20% is considered for the size reduction equipment. (Plant
Design and Economics 5th ed. p.82, by Timmerhaus and Peters).
2. The material of construction use is Gray cast Iron since the hardness of alimasag
shells fall on calcite material on Mohr’s Hardness Scale which has 135 Vickers. 135
Vickers is equivalent to 135 Brinell Hardness, HB of 135. Ordinary gray cast iron has
a range of 140-200 HB. (http://www.atlasfdry.com/grayiron-hardness.htm, Table
3)
3. The tensile strength of gray cast iron is 138 MPa. (Perry RH, Chilton CH. Chemical
engineering handbook. New York 8th ed McGraw-Hill; p. 25-32., Table 25-7)
4. The roll pressure is 6 MPa. (Rashidi, etal. A Review of the Modeling of High
Pressure Grinding Rolls)
5. The friction coefficient between the gray cast iron and alimasag shells is
considered 0.25-0.30 since the friction coefficient of paper to gray cast iron is
ranges from 0.25-0.30. The average is 0.275 and considered to be the fiction
coefficient. (https://www.engineeringtoolbox.com/friction-coefficients-
d_778.html)
Technical
6. The reduction ratio of double roll crusher 4:1.

(http://www.atlasfdry.com/grayiron-hardness.htm, Table 3)
7. The speed (rpm) of the motor is 200 rpm.
(https://www.911metallurgist.com/blog/roll-crushers).
8. The nip angle ranges from 10o to 20o. The average angle is taken which is 15o.
(Mörsky P, Klemetti M, Knuutinen T. Proc. International Mineral Processing
Congress; Chapter 8, 1995. p. 55–8)
9. The work index of alimasag shell is 3.08 kWh/t. (Chemical Process Equipment –
Selection and Design by S. Walas, 1st ed., p. 342)
DESIGN REQUIREMENTS
1. Capacity
2. Roller Gap
3. Roll Diameter
4. Roll Width
5. Roll Thickness
6. Peripheral Speed
7. Ribbon Factor
8. Correctional Capacity for Power Requirement
9. Power Requirement
DESIGN CALCULATIONS
1. Capacity
Mass 1 batch mins
Capacity = Bulk Density x Safety factor x time
x 60 hour
1,340 kg 1 batch mins
Capacity = kg x 1.2 x 10 min
x 60 hr
567.9 3
m
Capacity = 16.9889 m3 /ℎ𝑟
Use: Capacity, m3 = 17.00 m3
Capacity, kg = 9648 kg
2. Roller Gap
Roller gap is the distance between the two rolls. The gap is measured
based on the reduction ratio of the equipment.
Roller Gap = feed size x reduction ratio

1
Roller Gap = 20mm x
4
𝑹𝒐𝒍𝒍𝒆𝒓 𝑮𝒂𝒑 = 𝟓 𝒎𝒎
Technical
3. Roll Diameter
The radius of the roll is given by (Wills BA. Mineral processing technology.
2nd ed Oxford, New York Pergamon Press; 1981):
L − dcosθ
R=
2(cosθ − 1)
Where:
R = the roll radius
L = distance between the rolls
d = particle size
θ = Nip angle
5 mm − 20cos15
R=
2(cos15 − 1)
R = 210.1081 mm
Diameter = 420.2161 mm or 0.42 m
Use: Diameter, m = 0.42 m
For Checking, a table is shown from the study of Adam Zanker entitled
Smooth Rolled Crusher.
Technical
Using the coefficient of internal friction of crushed material and roll

gap/spacing, we can determine the Diameter of the roll. With friction coefficient
between the gray cast iron and alimasag shells considered to be 0.275 and roll
gap is 5 mm and average diameter/feed size is 20 mm,
Diameter = 0.4 m or 400 mm
Use: Diameter, m = 0.42 m
4. Roll Width
The capacity Q of roll crushers is directly proportional to its width, W,

diameter, D and speed of revolution of rolls. Under continuous and steady
feeding conditions, the capacity is given by (Wills BA. Mineral processing
technology. 2nd ed Oxford, New York Pergamon Press; 1981):
Q = 188.5DWsLρB
Where: D = diameter of roll (m)
W = width of roll (m)
s = speed (rpm)
L = set or distance between rolls (m)
ρB = bulk SG of the mineral (t/m3)
Calculating for the roll width (m):

9.648x10−3 ton/hr = 188.5(0.42m)W(200)(0.005m)(0.5679 ton/m3 )
W = 0.21459 m
Use: Roll Width, m = 0.22 m
5. Roll Thickness
A hollow cylindrical shaft is used to build the roll; this hollow shaft’s
thickness must be calculated to check for its ability to withstand the compressive
strength of the incoming raw material.
Pxd
σt = 2t
; Eq 1-5 Strength of Materials by Pytel and Singer 4th ed, p. 24
where, t = thickness of the roll
Technical
σt = tensile strength of the roll
p = Roll pressure
Pd
t=
2σt
6 MPa x 0.42 m
t=
2(138 MPa)
t = 0.00913m or 9.13 mm
𝑼𝒔𝒆: 𝒕 = 𝟗. 𝟏𝟓 𝒎𝒎
6. Peripheral Speed
Peripheral velocity is the speed that a point in the circumference of two

rolls moves per second. It is obtained through a graph from 911 Metallurgy Corp.,
Using the feed size and diameter of the roll, peripheral speed can be
obtained. For the feed size in inches, it is 0.7874 in. (20mm); diameter of the roll, it
is 16.5354 in.; Thus:
ft m
vP = 700 or 3.5569
min s
𝒎
𝑼𝒔𝒆: 𝒗𝑷 = 𝟑. 𝟓𝟔
𝒔
7. Ribbon Factor
The actual production will depend on the ‘ribbon factor, RF’ given by the
expression. The ribbon factor is defined as the ratio of the actual tonnage
Technical
passing through the crusher to the tonnage of the theoretical solid-rock ribbon.
In practice, the actual capacity ranges from 25-75% of this calculated capacity,
Q. (Perry RH, Chilton CH. Chemical engineering handbook. New York 8th ed
McGraw-Hill; p. 21-60.). The formula from Otte O. Proc. Third Mill Operators Conf.,
Australasian Institute of Mining and Metallurgy: Cobar; May, 1988. 131–6 is:
Q
𝑅𝐹 = 0.0095x
vP LW
9.648x10−3 ton/hr
𝑅𝐹 = 0.0095x m
3.5569 x0.42mx 0.2116 m
s
𝑅𝐹 = 0.28995
𝑼𝒔𝒆: 𝑹𝑭 = 𝟎. 𝟐𝟗
8. Actual Capacity for Power Requirement
Using the ribbon factor, we can compute for the correctional capacity
using the formula by Otte O. Proc,
Q = 3600WLvP ρB R F
m
Q = 3600x(0.28995)x(0.21459 m)x (3.5569 ) x(0.005m)x(0.5679 ton/m3 )
s
Q corrected = 2.2623 ton/hr
𝐔𝐬𝐞: 𝐐𝐜𝐨𝐫𝐫𝐞𝐜𝐭𝐞𝐝 = 𝟐. 𝟐𝟕 𝐭𝐨𝐧/𝐡𝐫
For checking, the capacity of roll crushers is calculated from the ribbon
theory, according to the formula from Perry RH, Chilton CH. Chemical
engineering handbook. New York 8th ed McGraw-Hill; p. 21-60., equation 21-91,
Q = dLvp /2.96
Where: Q = capacity (cm3/min)
d = roll gap/spacing (cm)
L = width of roll (cm)
Technical
vp = peripheral speed (cm/min)
cm
Q = (0.5cm)x(21.459 cm)x (21336 ) /2.96
min
cm3 m3
Q = 77,339.3960 or 4.6404
min h
Q = 2.6353 ton/hr
Q corrected = 2.64 ton/hr
The percent difference between the two actual capacities is 18.18%. We

will use 2.27 ton/hr since the ribbon factor is calculated specifically while for the
2.60 tons/hr, the ribbon factor is on average from 25-75%.
9. Power Requirement
Within the same reduction ratio the power consumption of one motor for
roll crushers varies widely. The power required could be expressed by the general
equation:
P = capacity × reduction ratio ×work index
P = 2.2623 tons/hr x 4 × 3.08 kWh/ton
P = 27.8715 kW or 37.3757 hp / 2 (two motor is used)
Use: P = 18.20 hp
Technical
DESIGN SPECIFICATION
DOUBLE ROLL CRUSHER

Operating Data
Number of Units 1
Capacity 17.00 m3/hr
Materials of Construction Gray Cast Iron
Materials Handled Alimasag Shells
Density 567.9 kg/m3
Feed
Amount Charged 1,340 kg / batch
Feed Size 20 mm
Double Roll Crusher Design Data
Proposed Existing
1. Capacity 9,648 kg/hr 5-10 t/h
2. Roller Gap 5 mm 1-8mm
3. Roll Diameter 0.42 m -
4. Roll Width 0.22 m Up to 0.870 m
5. Roll Thickness 9.15 mm -
6. Peripheral Speed 3.56 m/s -
7. Ribbon Factor 0.29 -
8. Correctional Capacity for Power

2.27 tons/hr -
Requirement
9. Power Requirement 18.20 hp 11-30 kW (AC Motor)
Existing Equipment
Zhengzhou Hengxing Heavy Equipment Co.,
Supplier
Ltd. (Hengxing double roller crusher)
Technical
(ninabellahi*outlook.com/
https://www.facebook.com/bella.liu.3990418)
(https://www.alibaba.com/product-
detail/High-Quality-Smooth-Roll-Crusher-
Roll_60660237842.html?s=p)
No. 8 Hongye Road, West Hehuan Street,
Supplier Address High-Teeh Development Zone, Zhengzhou,
China
DESIGN CONFIGURATION
DOUBLE ROLL CRUSHER
Technical

02 - Double Roll Crusher

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02 - Double Roll Crusher

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PAMANTASAN NG LUNGSOD NG MAYNILA

College of Engineering and Technology

DOUBLE ROLL CRUSHER

Compression crushing is a process where raw materials are crushed to a particle

Based from Unit operations of Chemical Engineering by McCabe, smooth-roll

DESIGN PARTS AND ACCESSORIES

Figure 9.27 Parts of the Double Roll Mill

Table 9.29 Parts and Functions of the Double Roll Mill

This is where the size reduced alimasag be discharged.

Double Rolls This is the grinding media.

DATA AND ASSUMPTIONS

6. The reduction ratio of double roll crusher 4:1.

Roller Gap = feed size x reduction ratio

Diameter = 420.2161 mm or 0.42 m

Use: Diameter, m = 0.42 m

Using the coefficient of internal friction of crushed material and roll

Diameter = 0.4 m or 400 mm

Use: Diameter, m = 0.42 m

The capacity Q of roll crushers is directly proportional to its width, W,

Where: D = diameter of roll (m)

W = width of roll (m)

L = set or distance between rolls (m)

ρB = bulk SG of the mineral (t/m3)

Calculating for the roll width (m):

where, t = thickness of the roll

σt = tensile strength of the roll

Peripheral velocity is the speed that a point in the circumference of two

8. Actual Capacity for Power Requirement

Q corrected = 2.2623 ton/hr

𝐔𝐬𝐞: 𝐐𝐜𝐨𝐫𝐫𝐞𝐜𝐭𝐞𝐝 = 𝟐. 𝟐𝟕 𝐭𝐨𝐧/𝐡𝐫

Where: Q = capacity (cm3/min)

d = roll gap/spacing (cm)

L = width of roll (cm)

vp = peripheral speed (cm/min)

Q corrected = 2.64 ton/hr

The percent difference between the two actual capacities is 18.18%. We

P = capacity × reduction ratio ×work index

P = 2.2623 tons/hr x 4 × 3.08 kWh/ton

P = 27.8715 kW or 37.3757 hp / 2 (two motor is used)

DOUBLE ROLL CRUSHER

1. Capacity 9,648 kg/hr 5-10 t/h

2. Roller Gap 5 mm 1-8mm

3. Roll Diameter 0.42 m -

4. Roll Width 0.22 m Up to 0.870 m

5. Roll Thickness 9.15 mm -

6. Peripheral Speed 3.56 m/s -

7. Ribbon Factor 0.29 -

8. Correctional Capacity for Power

9. Power Requirement 18.20 hp 11-30 kW (AC Motor)

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