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Examples of Industrial Crusher Applications
See How Gundlach Crushers Are Uniquely Focused on the End Product You Need to Make
Below, you’ll find examples of how Gundlach roll crushers and cage mills are particularly capable where secondary crushing is required to make final product.
You’ll also find examples where Gundlach two-stage, four roll crushers and breakers are used in primary crushing applications, letting you skip the second step and go straight to quality product.
Gundlach engineers have the crusher know-how to design and manufacture a system that helps you meet your product specifications. Plus, every Gundlach crusher engineer has the practical field experience to devise the critical maintenance-friendly designs that save you time and labor over many years of productive crusher operation.
From ash to vermiculite, there is a wide range of materials that Gundlach crushers can handle, including clays, coal, fertilizer, lime, potash and salts.
Cage Mills Used in Advanced Coal Processing to Make Coke at an Indiana Steel Mill
An Indiana USA steel mill installed this environmentally-friendly advanced coke system, which employs Gundlach's Cage-Paktor cage mills to crush coal.
To create the coke, many different types of coal are required. The system needs to be easy to adjust to assure consistent end product without interrupting production.
Gundlach supplied Cage-Paktor cage mills to crush coal to a 3 mm product and minimize fines. The Cage-Paktor cage mills are equipped with Hydrostatic drives to allow changing product size without interrupting production.
This special cage mill feature allows the plant to produce a uniformly-sized product in several product ranges.
Boiler Feed Coal Sizing and Bottom Ash Handling at a Canadian Mine and Power Plant
A Canadian power plant and mine uses Gundlach Roll Crushers for sizing coal to a boiler feed size.
After burning, the bottom ash is crushed by another Gundlach Roll Crusher.
The plant can then sell the bottom ash for fill or aggregate.
Roll Crusher Reduces Coal Ash Clinker for Conveying
This Single-Stage, Two Roll Crusher for bottom ash is installed at a coal fired power plant.
The roll crusher reduces the oversized ash for conveying to the bottom ash storage silo.
A single drive motor with gearbox allows the crusher to produce a uniform 4 inch product.
The crusher rolls use cast segments for improved wear life. Gundlach designs and manufactures roll designs that are configured to meet many different crushing needs. All Gundlach roll designs are thoroughly tested for sizing, durability and consistency to ensure reliable results.
Cage Mill Does Fine Grinding for Industrial Minerals
The Cage-Paktor cage mill provides maximum yield sizing of industrial minerals such as salt, lime, potash and similar materials.
Its unique Shaft-Within-a-Shaft design makes the Cage-Paktor a more compact cage mill, which takes up less floor space. The design also keeps the motor(s) to one side, making for far easier maintenance than other cage mills.
This is just one of the features in Gundlach's design for easy maintenance of its cage mills. The swing-away door opens without removing any components to give immediate cage access. An optional on-board cage removal jib crane swings into position to remove cages for repair without the need of overhead cranes or extra help.
Coke Crushers Save Money for Large Oil Refinery in India
Gundlach engineers have helped many oil refineries and others save money and become more efficient by designing and providing crusher solutions for handling different kinds of coke.
Gundlach designed and delivered the largest coke crushing plant in the world at a refinery in India.
The refinery has two electric, mobile crushing plants receiving coke from an overhead clamshell bucket.
These mobile crushing plants use Gundlach Two-Stage, Four Roll Crushers to handle up to 1 meter lumps at 800 TPH.
Gundlach Roll Crushers Solve 'Impossible' Application for Chemical Plant Needing to Crush Hot Materials
Handling high-temperature materials had posed a serious and costly problem to plant management of a Northern USA Chemical Plant.
Gundlach designed a 3000 Series, Single-Stage, Two Roll Crusher to reduce materials, which have been heated to 1800 degrees Fahrenheit (980° C).
This is an application that previously had been thought to be impossible. Gundlach crushers made the impossible possible.
Green Petroleum Coke Crusher
The receiving hopper together with a Single-Stage Two Roll Crusher runs alongside a petroleum coke pit on rails and receives petroleum coke from an overhead clamshell bucket. Up to 36 inch diameter lumps drop into the receiving hopper that contains slotted grizzly bars with plus 12 inch material being returned by gravity to the pit.
A vibrating feeder located below the hopper meters the material into a Gundlach Single-Stage Two Roll Crusher. Crushed material discharges directly onto a product take away belt conveyor.
Gundlach Roll Crusher Benefits:
- Up to 50% FEWER fines
- INSTANT product adjustment while running-without tools
- AUTOMATIC tramp iron relief system
- NO screens and NO plugging
Gundlach Roll Crusher Specifications:
- Material: petroleum coke
- Feed: 12 inch by 0 inch
- Product: 2 inch by 0 inch
- Capacity: 675 MTPH
- Unit: 4060S Single-Stage Two Roll Crusher
- HP: Two 75 HP TEFC Motors
Roll Crushers Reduce Raw Nickel Ore with High Moisture Content
A South American Nickel Mining company had a requirement to crush raw ore with a high moisture content.
This very sticky problem was solved by two Gundlach Single-Stage Roll Crushers operating with special features to keep the material flowing.
Gundlach roll crushers have demonstrated proven results in wet, dry, hot, cold, sticky, hard and abrasive crushing applications.
There are Gundlach roll crushers designed for applications ranging from run-of-mine material through fine sizing. Gundlach makes hundreds of roll configurations to meet your crushing needs.
Wet Salt in Closed Circuit
A Cage-Paktor cage mill is installed to crush wet salt at a solar salt plant.
The cage mill is a 30 inch diameter model with single drive motor.
Wet oversized salt is conveyed into the mill. The Gundlach cage mill efficiently reduces the salt to 20 mesh particles for the dryer.
The mill contains wet scrapper bars to prevent salt build up.
Replaceable "wrap-around" striking plates offer increased tonnage life plus wear protection to the structural members and are replaceable without dismantling any other components.
Material enters directly into the Cage-Paktor's center through the low-friction inlet chute. Only particles large enough in mass are affected as they pass through the counter-rotating cages. Already-to-size particles produced from previous stages of reduction are not reduced, and so less fines are created. The multiple stages of crushing inside the Cage-Paktor minimize product oversize, achieving greater crushing efficiency and producing more product in the size range desired.
Roll Crusher Eliminates Secondary Crushers and Screening Plant in Underground Rock Salt Processing
A major salt mine was faced with an unreliable closed circuit screening system with both primary and reject crushers.
Testing confirmed that a single low maintenance Gundlach Roll Crusher would eliminate oversized material and the need for screening. Testing also showed that the roll crusher could produce a higher product yield. Sized material could now discharge directly onto the product belt and meet customer specifications in one pass without the need for additional screening or crushing equipment.
Gundlach installed a Two-Stage, Four Roll Crusher to crush the rock salt. The inlet feed size was 8 to 10 inches x 0 and was reduced to Nominal 1/2 inch x 0.
This single Gundlach roll crusher eliminated 2 existing crushers and a screening plant. It also eliminated a full time house keeping function.
Calcined Petroleum Coke Crusher
This Single-Stage, Two Roll Crusher for green petroleum coke is installed at a calcining plant.
Gundlach crushers are used in this application for conditioning pet coke for the calciner and for sizing the calcined coke product.
The Gundlach Two Roll Crusher employs a single drive motor with gearbox for making a 3-dimensional crush for a 2 inch product. The Gundlach roll crusher is the only capable of 3-D crushing.
