Overall Structure and Core Components
The horizontal crusher features a modular, integrated design and consists primarily of the following six major systems:
(I) Housing System: Comprising the feed hopper, main casing, discharge outlet, and quick-opening access doors. The housing is constructed from welded high-quality steel plate, ensuring a robust structure. To prevent material adhesion and wear on the steel casing, the interior is lined with rubber or polypropylene sheets. Quick-opening access doors are located on both sides of the housing to facilitate daily inspection, cleaning, and maintenance.
(II) Dual-Rotor System: This is the core working component of the equipment, consisting of two horizontally arranged main shafts, rotor frames, parallel keys, shaft sleeves, and bearings. The crusher utilizes a dual-rotor configuration, with each rotor shaft driven by an independent motor. Mounted on each shaft is a rotor assembly featuring steel ring chains; one end of each chain connects to the rotor, while the other end is fitted with a wear-resistant steel chain head. The main shafts are supported by heavy-duty roller bearings, ensuring stability under high material loads and extending bearing service life.
(III) Drive System: Comprising two electric motors, pulleys, V-belts, and vibration dampers. Each rotor shaft is powered by its own dedicated motor. A speed-increasing pulley arrangement ensures smooth, high-speed operation of the main shafts. The drive assembly is mounted on a structural steel base, which is connected to the foundation via vibration dampers. This design enables rapid material pulverization.
(IV) Shrink-Disc Coupling and Overload Protection: The system employs shrink-disc couplings for connection; these generate clamping force through normal pressure and transmit torque via the resulting friction. This method offers advantages such as high torque transmission, excellent alignment, a simple and reliable structure, and ease of assembly/disassembly, while also providing cushioning and overload protection. Both the belt drive and the shrink-disc couplings contribute to the system's overload protection capabilities. (V) Adjustment mechanism: Uses bolts, nuts, and shims for adjustment. Featuring a simple structure, ease of maintenance, and flexible, rapid operation, it allows for the adjustment of the clearance between the grinding hammers and the impact plates to compensate for wear.
Applicable Fields and Industry Coverage
Horizontal crushers have a wide range of applications. In fertilizer production, they are among the most commonly used crushing machines for compound fertilizers, organic fertilizers, and bio-fertilizers, suitable for processing both raw materials and recycled material; they can crush large fertilizer lumps (average diameter >4 mm) into granular fertilizer with an average diameter of 1–4 mm. In the chemical industry, they are used to crush bulk chemical raw materials such as ammonium bicarbonate, ammonium chloride, and monoammonium phosphate. In the construction materials and mining sectors, they are used to crush various materials, including limestone, cement clinker, gypsum, coal gangue, slag, copper ore, and iron ore. In the organic fertilizer sector, they are used to crush high-moisture, biologically fermented materials, such as fermented organic compost, municipal solid waste compost, peat, agricultural straw waste, industrial organic waste, and livestock manure.
Types of usable raw materials
The horizontal crusher is capable of processing a wide variety of raw materials. These include: fertilizer raw materials (such as ordinary superphosphate, phosphate fertilizers, soda ash, ammonium chloride, potassium chloride, potassium sulfate, urea, monoammonium phosphate, diammonium phosphate, and various compound fertilizers containing phosphorus and potassium); organic materials (such as lumpy livestock and poultry manure—both pre- and post-fermentation—municipal solid waste, peat, agricultural crop residue, and industrial organic waste); and industrial minerals (such as limestone, cement clinker, gypsum, coal gangue, slag, copper ore, and iron ore). The equipment is particularly well-suited for crushing lumpy fertilizers and other materials of medium hardness.
Operating Principle and Comminution Mechanism
The working principle of the horizontal crusher is based on a synergistic crushing mechanism combining "counter-rotating high-speed dual rotors" and "chain impact." Its operation proceeds in three stages:
Feeding and initial impact stage: Material enters the casing through the inlet and flows over a distribution plate toward the area above the chains, where it first collides with the high-speed rotating chains. The material undergoes violent strikes from the chains, resulting in initial breakage.
Multi-stage impact and crushing stage: The horizontal crusher features a dual-rotor structure, with each rotor shaft rotating independently at high speed. After being struck by the chains on one rotor, the material is propelled toward the other rotor, where it is struck again. Inside the casing, the material collides with the high-speed chains—undergoing impact, compression, and fragmentation—and also rebounds off the inner casing walls to collide with high-manganese steel impact bars. The circumferential speed of the chain heads ranges from 28 to 78 m/s. As the material falls, it undergoes repeated impacts, reducing it to a powder or granules smaller than 3 mm.
Discharge stage: The crushed material is discharged through the bottom outlet. As the equipment is designed without a screen plate, the material can be discharged directly, minimizing the risk of clogging.
