Chain Crusher

Chain Crusher

The chain crusher is an impact-type crushing device that pulverizes material lumps through the action of high-speed rotating chains. It is one of the most commonly used crushing machines in the production of compound and organic fertilizers. The equipment utilizes high-strength, wear-resistant cemented carbide chain plates operating at synchronous speeds; its well-designed inlet and outlet ensure uniform crushing, minimize material adhesion to the inner walls, and facilitate easy cleaning.

This crusher is suitable for breaking down lumps in compound fertilizer production, as well as processing materials such as organic fertilizers and potash fertilizers. It can handle products like ordinary superphosphate (with 14% moisture and 6% free acid content) and various phosphorus-potassium compound fertilizers, effectively overcoming the issue of material sticking to the inner casing—a problem that often halts production. In the organic fertilizer sector, the chain crusher efficiently pulverizes various lumpy raw materials and recycled fines—including livestock manure (both pre- and post-fermentation) and industrial sludge.

The chain crusher offers the advantages of a simple structure, low cost, and excellent crushing performance. It employs high-strength, wear-resistant cemented carbide chain plates, and features a well-designed inlet and outlet that ensure uniform crushing, prevent wall adhesion, and allow for easy cleaning.

Overall Structure and Core Components

Chain crushers are categorized by installation configuration into vertical and horizontal types; the vertical model features a single-rotor design, while the horizontal model utilizes a dual-rotor design. Featuring a scientifically sound structural design, the equipment comprises the following core components:

(I) Frame and Casing Assembly: Includes the lower frame and the casing assembly. The casing assembly is mounted on the lower frame, serving as the load-bearing foundation for the entire unit. To prevent material adhesion and friction against the steel casing, the interior is lined with rubber or polypropylene sheets. Quick-opening access doors are provided on both sides of the casing to facilitate daily inspection, cleaning, and maintenance.

(II) Rotor and Main Shaft System: Includes the main shaft, upper and lower bearing housings, and rotor discs. Power is transmitted via a coupling to rotate the main shaft, which is supported by bearing housings mounted at the top and bottom of the casing. The rotor discs, mounted on the main shaft, serve as the core components for attaching the chains; they are equipped with high-strength, wear-resistant carbide chain plates that rotate synchronously.

(III) Chains and Crushing Components: Includes chains, link-end heads, hammer heads, and hammer blades. The primary working component is the rotor equipped with steel link chains; one end of each chain connects to the rotor, while the other end is fitted with a link-end head made of wear-resistant steel. As an impact-type crusher, it pulverizes material lumps through the impact of high-speed rotating chains. The crushing chains utilize a composite manufacturing process—combining a carburized steel base with a carbide wear-resistant layer—to effectively extend service life.

(IV) Feeding and Discharge Devices: Includes the feed hopper and discharge outlet. The feed hopper is mounted on the upper part of the casing, while the discharge outlet is located at the bottom; both are designed to ensure smooth material flow.

(V) Transmission and Drive System: Includes the motor mount, drive motor, and V-belt transmission mechanism. The horizontal chain crusher employs a dual-rotor structure, with each rotor shaft driven by its own motor. A V-belt transmission system is used, allowing for adjustable main shaft speeds. The main unit and drive assembly are mounted on a structural steel base; vibration isolators are installed beneath the base to connect it to the foundation.

(VI) Motor and electrical system: Includes the electric motor, motor mount, and associated electrical control equipment. Motor power varies by model, with common configurations ranging from 11 kW to 55 kW.

Operating Principles and Forming Mechanisms

The chain crusher is a type of impact crushing equipment. Its operating principle relies on the impact and pulverization of material by high-speed rotating chains.

Material drops from the feed hopper into the crushing chamber, where it is pulverized by the impact of high-speed rotating link chains and by collisions between the material particles themselves. Simultaneously, centrifugal force throws the material against the inner wall of the chamber, causing further breakage upon impact; the material then falls onto the rotational plane of the next set of chains for continued crushing.

Taking a horizontal twin-rotor chain crusher as an example: material enters the machine through the inlet and is struck by the chains of one rotor, propelling it toward the other rotor where it is struck again. After undergoing repeated collisions and impacts, the material is discharged from the bottom of the machine, completing the crushing process. The granularity of the crushed material can be adjusted by increasing or decreasing the number of chains. The circumferential speed of the chain tips ranges from 28 to 78 m/s.

Core Advantages and Performance Highlights

The chain crusher offers the following outstanding advantages: Uniform material crushing—utilizes high-strength, wear-resistant carbide chain plates operating at synchronized speeds to ensure consistent crushing. Resistance to wall adhesion—the interior is lined with rubber or polypropylene plates, effectively preventing material buildup. Ease of cleaning—features a well-designed inlet and outlet, along with quick-opening access doors. Continuous production—horizontal models enable continuous operation, thereby boosting productivity. Corrosion resistance—capable of processing specialized materials containing up to 6% free acid. Sound structural design—scientifically engineered for stable and reliable operation.

Types of usable raw materials

The chain crusher is capable of processing a wide variety of raw materials. These include organic fertilizer materials such as animal manure (chicken, pig, cattle, etc.), household waste, fallen leaves and branches, biogas residue, and spent mushroom substrate, as well as lumpy livestock manure (both pre- and post-fermentation) and industrial sludge. Chemical fertilizer materials include large lumps of ammonium bicarbonate, ammonium chloride, and monoammonium phosphate, along with ordinary superphosphate, compound fertilizers, and potash fertilizers. Industrial raw materials include low-to-medium hardness non-metallic minerals (such as limestone and dolomite), soda ash, dry clay, shale, and earthy limestone. The equipment is suitable for crushing various brittle materials—whether in lump or strip form—that have low structural strength, as well as agglomerated granular materials.