Industrial Crusher Applications

Advanced Coal Processing

An Indiana USA steel mill uses an environmentally-friendly advanced coke system. 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 Technology to crush coal to a 3 mm product and to minimize fines. The Cage-Paktors are equipped with Hydrostatic drives to allow changing product size without interrupting production. This allows the plant to produce a uniformly-sized product in several product ranges.

Coal and Bottom Ash Handling

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.

Coal Ash Clinker

Double Roll Single-Stage Crusher for bottom ash at a coal fired power plant.

Crusher reduces the oversized ash for conveying to the bottom ash storage silo.

Single drive motor with gearbox allows the crusher to produce a uniform 4 inch product.

Rolls use cast segments for improved wear life.

Coal Power for the Future

Circulating Fluidized Bed (CFB) technology is the technology of the future for the coal-fired thermal power industry. CFB mixes coal with limestone to greatly reduce the sulfur content of emissions.

Cage-Paktor can also be used to make the spec limestone needed when in a closed circuit system.

Mobile or Stationary Petroleum Coke Crushers

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.

Electric Power Plant: Jiawang, China

• Model 75B Cage-Paktor
  
  
• 310 RPM
  
  
• 450/315 Kw Motors
  
  
• Feed: 50 mm X 0, Occ. 80mm
  
  
• Prod: 99%<10 mm
  
  
• Cap: 350-400 MTPH
  
  

Produces superior product size and shape for most efficient use of CFB technology.

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, an application that previously had been thought to be impossible.

Mobile Petroleum Coke Crusher System

Receiving hopper and 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.

Benefits:

• Up to 50% FEWER fines
  
  
• INSTANT product adjustment while running-without tools!
  
  
• AUTOMATIC tramp iron relief system
  
  
• NO screens and NO plugging
  
  

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
  
  

Nickel Ore

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.

Petroleum Coke Crusher

Single-Stage Two Roll Crusher for green petroleum coke at a calcining plant.

Crusher conditions the pet coke for the calciner.

Single drive motor with gearbox for making a 3-dimensional crush for a 2 inch product.

Separating Wet Fines

The rotating action of the Ro-Pro Separator makes an ideal solution for a coal processing plant wanting to separate the ash free coal fines prior to washing. The unique feature of Ro-Pro technology is its ability to maintain separating efficiency in high-moisture applications where normal screens blind. The Ro-Pro maximizes wash plant capacity, maximizing shipped product and keeping ash below customer specification.

Wet Salt in Closed Circuit

Cage-Paktor cage mill, 30 inch diameter with single drive motor to crush wet salt at a solar salt plant.

Wet oversized salt is conveyed into the mill which reduces the material to 20 mesh particles for the dryer.

Mill contains wet scrapper bars to prevent salt build up.

Underground Rock Salt Processing

A customer had an unreliable closed circuit screening system with both primary and reject crusher.

Gundlach provided a better solution. In house testing confirmed that a low maintenance roll crusher would eliminate the oversized and need for screening while giving them a higher product yield. Sized material discharges directly onto the product belt. The customer's specifications are met 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 eliminated 2 existing crushers and a screening plant. It also eliminated a full time house keeping function.