Hammer Crusher
Screenless Two Stage Hammer Crusher Coal Gangue Double Stage Hammer Crusher Fine Reduction Mill
Item Number: PP-HC09
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Product Overview
This advanced dual-stage hammer crusher represents a significant engineering achievement in heavy-duty size reduction for high-moisture, highly viscous bulk materials. By combining two distinct crushing zones in series within a single vertical housing—completely eliminating the traditional bottom screen grate—this equipment solves the long-standing industry challenge of material jamming, screen blinding, and operational downtime. The system provides continuous, high-efficiency fine reduction, converting coarse input materials into fine particles with exceptional consistency.
Specifically optimized for brick and tile manufacturing, metallurgical processing, cement production, and industrial waste recycling, this unit excels at grinding challenging feeds such as wet coal gangue, boiler slag, shale, and construction debris. It enables brick manufacturing plants to process wet raw materials down to the precise particle sizes required for internal fuel blending and hollow brick body preparation, dramatically improving thermal efficiency and green body structural integrity.
Constructed with heavy-gauge structural steel and high-alloy internal wear components, the machine delivers unwavering reliability under demanding industrial conditions. Driven by twin independent motors, the dual-rotor kinetic design ensures low-vibration operation, maximum energy conversion, and sustained performance even when operating in adverse weather conditions or handling sticky feedstocks with elevated moisture levels.
Key Features
- Dual-Rotor Series Kinetic Architecture: The system integrates upper and lower high-speed rotors operating in series within a single crushing chamber. Primary impacts from the upper rotor break down coarse feed and immediately hurl material into the lower high-speed hammer path, creating high-frequency inter-particle collisions that double crushing efficiency.
- Grate-Free Screenless Bottom Design: Designed without a traditional discharge screen or grate bar assembly, this unit handles sticky, high-viscosity, and wet materials with moisture content up to 35% without clogging, bridging, or stopping production during humid conditions.
- Composite Wear-Resistant Alloy Hammers: Outfitted with advanced metallurgically bonded composite alloy hammer heads, the equipment offers superior impact resistance and exceptional surface hardness, significantly extending service life and reducing replacement frequency under high-abrasion regimes.
- Adjustable Discharge Particle Control: Output fine fraction size is easily adjustable to maintain a consistent output of 3 mm or less. The adjustment mechanism is decoupled from hammer wear, ensuring output granulometry remains uniform throughout the life of the wear components.
- Multi-Channel Discharge and Dust Minimization: Multi-path discharge geometry accelerates material evacuation from the crushing zone, minimizing internal dust circulation and re-grinding while eliminating the immediate necessity for complex auxiliary dust collection infrastructure.
- High-Efficiency Twin Motor Drive System: Dual motors provide dedicated power to each rotor independently. This optimized kinetic configuration delivers over 40% electrical energy savings compared to single-stage or conventional multi-crusher setups achieving equivalent throughput.
- Rapid Access Inspection and Maintenance Doors: The main housing features quick-opening access hatches that allow technicians to perform routine hammer inspections and replacements directly without dismantling the main chassis or drive train assemblies.
- Heavy-Duty Machined Shafts and Pulley Hubs: Shafting and motor pulleys are precision-machined from forged alloy steel, ensuring zero rotational fatigue, high thermal stability, and long-term dimensional stability without premature wear.
Applications
| Application | Description | Key Benefit |
|---|---|---|
| Coal Gangue Reduction for Brickworks | Fine crushing of high-moisture coal gangue for use as internal fuel and body material in brick plants. | Achieves <3 mm output without screen clogging, optimizing fuel distribution and firing consistency. |
| Boiler Slag & Clinker Processing | Reduction of dense industrial boiler slag, coal ash, and clinker into fine mineral additives. | High-hardness composite hammers resist severe abrasion, lowering cost-per-ton processing. |
| Shale & Clay Milling for Hollow Bricks | Fine milling of wet shale and clay minerals for thin-walled hollow brick manufacturing. | Constant particle size distribution yields higher green body strength and fewer structural defects. |
| Construction Waste Recycling | Processing crushed concrete, masonry debris, and plaster for recycled aggregate production. | Handles mixed moisture waste streams continuously without clogging machine discharge ports. |
| Metallurgical Flux Preparation | Crushing raw metallurgical additives, ores, and sinter feedstocks prior to agglomeration. | High throughput capacity with dual kinetic energy impact delivers rapid size reduction. |
| Cement Plant Raw Material Prep | Pre-crushing secondary raw materials and additives before ball mill or vertical roller mill feeding. | Cuts overall plant energy consumption by over 40% through efficient primary/secondary impact reduction. |
Technical Specifications
| Specification Parameter | Variant PP-HC09-400x600 | Variant PP-HC09-600x600 |
|---|---|---|
| Base Product Identifier | PP-HC09 | PP-HC09 |
| Sub-Model Designation | PP-HC09-400x600 | PP-HC09-600x600 |
| Maximum Feed Size (mm) | 80 | 100 |
| Output Particle Size (mm) | ≤ 3 | ≤ 3 |
| Production Capacity (t/h) | 8 – 15 | 10 – 30 |
| Max Permissible Moisture (%) | < 35 | < 35 |
| Motor Power Configuration (kW) | 22 + 22 (44 Total) | 45 + 45 (90 Total) |
| Rotor Configuration | Dual Series Rotors | Dual Series Rotors |
| Discharge Bottom Type | Screenless / Grate-Free | Screenless / Grate-Free |
| Hammer Material | Composite Wear Alloy | Composite Wear Alloy |
| Maintenance Access Type | Quick-Open Inspection Port | Quick-Open Inspection Port |
Why Choose This Product
- Unmatched Moisture Handling Capability: Eliminates production shutdowns caused by material sticking and screen clogging, allowing operations to maintain full capacity even when processing high-humidity feeds or working in rainy weather.
- Exceptional Operational Energy Savings: Synchronized dual-rotor engineering delivers up to 40% lower kilowatt-hour power consumption per ton of processed material compared to conventional crushing lines.
- Low Maintenance Downtime: Quick-access inspection hatches and long-life composite alloy hammers permit rapid inline servicing without requiring major disassembly or heavy crane intervention.
- Robust Heavy-Duty Build Quality: Engineered with reinforced structural steel frameworks, precision forged shafts, and wear-resistant liners designed to withstand continuous multi-shift industrial operation.
- Comprehensive Process Customization: Available in multiple dimensional configurations and power ratings to align perfectly with specific plant throughput requirements and material characteristics.
Contact our application engineering team today to request a detailed technical proposal or discuss customized sample preparation and material processing configurations tailored to your facility.
REQUEST A QUOTE
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