CPC Crusher & Mills

CPC Double Roll Crusher

Application

The CPC Double Roll Crusher is a versatile tool for coarse crushing of hard and medium-hard materials such as limestone, magnesia, salt, fertilizer and coal. Capable of processing up to 2,500 tons per hour and handling feed material up to 1,200 mm in size, this crusher offers flexible product particle sizes ranging from 10 mm to 300 mm. It is ideal for integration into semi-mobile plants and can be customized to meet specific customer requirements, including the design of the crushing teeth based on the type of material.

Operation

The CPC Double Roll Crusher operates by crushing the feed material using both teeth and hydraulically induced pressure, allowing for successive crushing of larger lumps. The particle size of the product is controlled by precisely adjusting the gap between the rolls. A unique feature is the ability to open the gap between the crushing rolls in the event of an overload, such as when an unbreakable foreign object is encountered, thus avoiding a shutdown. In addition, specially designed scrapers prevent clogging of the rolls by sticky material, and the limited speed of the rolls ensures a final product with a low proportion of fines.

Features

The CPC Double Roll Crusher has an exceptionally long life due to the welded hard facing of the crushing teeth. Single segment plates with crushing teeth allow easy replacement of wear parts without dismantling the entire roll. Maintenance is simplified with the motor/gear drive (alternatively V-belt drive), including speed control and overload protection. An integrated flywheel compensates for torque peaks, reducing the amount of motor power required. Special shaft and housing seals on the moving roller prevent dust ingress, and inert gas operation is available where required. Other features include stainless steel housing parts in contact with the feed material, guaranteed permanent parallel positioning of the crushing rolls, and extremely fast movement of the movable crushing roll without critical cavitation of the hydraulic oil. The crusher also features an automatic central lubrication system for the shaft bearings and a Local Operating Panel (LOP) with PLC.

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CPC Hybrid Crusher

Application

The CPC Hybrid Crusher excels at coarse crushing a wide range of materials from hard, medium-hard to soft such as limestone, dolomite, magnesia, salt, coal, clay and oil shale. This robust crusher can process up to 5,500 tons per hour, depending on material characteristics and particle size. It accepts feed material up to 1,500 mm in size, with the ability to reduce the particle size down to 300 mm and even as small as 50 mm for secondary crushing stages. The crusher design is tailored to the material requirements, including the number, size, position, shape and hardness of the crushing teeth.

Operation

The CPC Hybrid Crusher uniquely combines the characteristics of the Double Roll Crusher with the performance of the Sizer to provide a highly efficient crushing process. It works by the interplay of teeth on two counter-rotating rolls, allowing successive crushing of larger lumps. The output particle size is finely controlled by precise adjustment of the roll gap. A notable feature is the crusher’s ability to open the gap between the crushing rolls within milliseconds in the event of an overload, such as when an unbreakable foreign object is encountered, thus preventing a shutdown. The crushing teeth are spirally arranged on the shaft to balance torque peaks, and the design includes special scrapers to prevent clogging by sticky materials. The limited speed of the rollers ensures an end product with a low proportion of fines.

Features

The CPC Hybrid Crusher offers a unique combination of efficiency and versatility to process a wide range of materials of varying hardness and size. Precise control over particle size output, combined with the ability to handle high throughput, makes it an ideal choice for a variety of crushing requirements.

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CPC Sizer

Application

The CPC Sizer is adept at coarse crushing medium-hard and soft materials, including salt, coal, phosphate and clay. This efficient crusher can handle throughputs up to 4,000 tons per hour, depending on material characteristics and particle size. It can process feed material up to 1,500 mm and reduce it to a product particle size as small as 300 mm. The design of the crushing teeth is tailored to the specific material requirements, including their number, size, position, shape and hardness. In addition, the CPC Sizer can be seamlessly integrated into semi-mobile equipment, making it a versatile choice for various industrial applications.

Operation

The CPC Sizer operates by the action of two counter-rotating rollers. These rolls can be either inward rotating (Center Sizer) for efficient pre-crushing or outward rotating against lined housing walls (Side Sizer) for effective media crushing. This system allows successive crushing of larger lumps while allowing fine feed material to pass through unobstructed. Specially designed scrapers prevent sticky material from clogging the rolls. The limited speed of the rolls also contributes to a low fines content in the final product.

Features

The CPC Sizer has an exceptionally long service life, due in large part to the welded hard facing of the crushing teeth. The crushing teeth are spirally arranged on the shaft to balance torque peaks and improve overall efficiency. The segment plates with the crushing teeth are designed for easy maintenance, as there’s no need to disassemble the entire roll for replacement. The shafts are typically solid and can be bolted or clamped to the segment plates. The side sizers have sloped side walls to reduce jamming. Maintenance is further simplified by the motor/gear drive, including speed control and overload protection. Where necessary, stainless steel housing elements are in contact with the product to ensure durability. The CPC Sizer also features an automatic central lubrication system for the shaft bearings and is designed with a discharge seal that allows for easy and quick movement to a maintenance position. For added convenience and integration, it is supplied with a Local Operating Panel (LOP) equipped with PLC and communication interface for plant control units.

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CPC Smooth Roller Mill

Application

The CPC Smooth Roller Mill is designed for grinding hard and medium-hard materials such as limestone, magnesium oxide, salt, fertilizer and coke. With a feed capacity of up to 500 tons per hour, it excels in fine grinding. For example, it can efficiently reduce a 30 mm feed size to a 5 mm finished product, achieving approximately 80% of the target particle size while largely eliminating fine fractions and dust. The roll surface is adaptable to the material properties and can be smooth, machine-cut grooved or built up with welded cracks, increasing its versatility. In addition, the mill can be integrated into semi-mobile installations, making it a flexible option for various industrial environments.

Operation

The CPC Smooth Roller Mill grinds the feed material by applying a mechanical pressure of 200 to 400 kN between two hydraulically driven rollers (fixed and moving). The particle size is precisely controlled by hydraulic adjustment of the roller gap. In the event of an overload, such as an unbreakable foreign object, the gap between the crushing rollers can be opened in milliseconds, allowing the object to pass and preventing a shutdown. This feature ensures continuous, uninterrupted operation.

Features

The CPC Smooth Roller Mill has an exceptionally long life due to its extremely hard chrome alloy rollers. Maintenance is minimal due to its motor/transmission drive (alternatively, V-belt drive). The mill is equipped with speed control and overload protection for efficient and safe operation. It can start under load, reducing downtime. Special shaft and housing seals on the moving roller prevent dust emissions, and inert gas operation is available if required. Stainless steel is used for machine parts that come in contact with the feed material, ensuring durability and hygiene. The mill guarantees a permanent parallel position of the crushing rolls, even under partial overload conditions, thanks to the hydraulic “crossing” of the hydraulic cylinders. The design and dimensioning of the hydraulic elements allow an extremely fast movement of the mobile shaft without critical cavitation of the hydraulic oil. Hydraulic controls are located on a single manifold, minimizing the need for delicate piping. Other features include automatic, centrally lubricated axle bearings, optional shock absorbers, a design that allows quick and easy movement to the maintenance position, and a PLC control panel. The mill also offers a communication interface with available plant controllers to ensure seamless integration into existing systems.

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CPC Hammer Mill

Application

CPC hammer mills are designed to grind a wide variety of medium-hard and soft materials, including coal, limestone, gypsum, clay, marl, salts and phosphates. Their versatility extends to handling feed materials with increased moisture content, making them ideal for a wide range of industrial applications. A unique feature of these mills is their ability to simultaneously grind and dry by introducing hot process gas (e.g., flue gas from combustion), which increases the efficiency of material processing.

Operation

The CPC hammer mills operate by using impact hammers to crush coarse grains. The feed material is caught by the hammers and thrown against the grinding wall, effectively crushing it. The material is further crushed and shaped in the middle area of the grinding wall. For finer classification of the material, the lower section of the mill can be equipped with an adjustable grate. This multi-stage grinding process ensures a uniformly processed product.

Features

CPC Hammer Mills feature a modular hammer design that allows hammer heads to be replaced separately, increasing durability and reducing maintenance time. The hammer heads are made of a bimetallic composition that combines an extremely hard chromium alloy with a tough backing material for longer life. The rotor’s rigidity is maintained by a high preload during manufacture, ensuring no deflection even at widths up to 3 meters. Other features include a dynamically balanced rotor to DIN 1940 quality G6.3, V-belt or direct drive, and reversible direction of rotation to extend maintenance intervals. The grinding gap is externally adjustable and the mills are equipped with hydraulically folding grinding walls for easy maintenance. Options include electrically heated thermal oil heating to prevent material build-up, a local operator station with PLC for control and monitoring, a central lubrication station for the bearings, and the ability to mount the mill on a base plate with anti-vibration mounts. For environments requiring noise reduction, an optional sound enclosure is available to maintain a sound pressure level below 80 dB(A).