Equipment Introduction
The chain crusher is one of the most commonly used crushing equipment in the compound fertilizer industry, belonging to the impact crusher category. It employs high-strength, wear-resistant hard alloy chains and hammers rotating at synchronous speeds. The high-speed rotating chain repeatedly impacts, squeezes, and grinds the material, crushing lumpy materials into fine powder or small particles.
This equipment is highly adaptable to materials with high moisture content, is not prone to clogging, and ensures smooth feeding. It can crush undried phosphate fertilizers containing water and free acid, as well as various compound fertilizer products, overcoming the shortcomings of traditional crushers that are prone to sticking to the walls and clogging.
Equipment Structure
The chain crusher mainly consists of the following components:
| Component | Function Description |
|---|---|
| Lower Frame | Used for equipment support and installation; fixed on concrete foundation with anchor bolts. |
| Machine Housing | Encloses the crushing chamber; internally equipped with rubber liners or protective plates to reduce material sticking and protect the housing. |
| Main Shaft & Upper/Lower Bearings | The main shaft is supported by bearings installed on the upper and lower frames; it is the core rotating component. |
| Rotor Assembly | Installed on the main shaft and rotates at high speed with the main shaft. |
| Hammers / Hammer Blades | Connected to the rotor; material is crushed and sheared by high-speed impact and friction between hammer blades and toothed plates. |
| Motor Frame & Transmission Device | The motor drives the main shaft through a transmission belt; dual rotors are driven by independent motors for higher efficiency. |
| Feeding Hopper | Located on the upper part of the machine for uniform feeding. |
| Access Door / Inspection Door | Quick-opening access doors are provided on both sides of the machine housing for easy cleaning, inspection and maintenance. |
Structural Features:
Horizontal double rotor design, with the rotors enclosed within the machine body;
easy cleaning can be achieved by opening the side covers;
vibration dampers are installed at the bottom of the base to reduce operating vibration and noise.
Working Principle of the Equipment
The chain crusher operates on the basis of a high-speed impact crushing mechanism. The specific process is as follows:
1. Feeding: Material enters the machine casing from the feeding hopper and falls into the dual-rotor working area;
2. First-stage impact: A high-speed rotating chain (circumferential speed 28~78m/s) on one rotor strikes the material, impacting it against the other rotor;
3. Second-stage impact: The material is struck and impacted again by the chain on the opposite rotor, while simultaneously colliding and rebounding against the inner wall of the machine casing;
4. Repeated grinding: During its descent, the material undergoes multiple impacts, compression, and grinding by the chain, hammers, and the inner wall of the machine casing;
5. Discharge: The material gradually becomes powder or particles smaller than 3mm and is discharged from the lower outlet.
Particle size adjustment: The fineness of the crushing is controlled by increasing or decreasing the number of chains. The more chains, the finer the crushing; when operating at the optimal load with all chains fully loaded, the material can be crushed to below 1mm.
Applications of the Equipment
Chain crushers are widely used in the following fields:
1. Fertilizer industry: Crushing of granular compound fertilizers, superphosphate, heavy calcium carbonate, phosphate fertilizers, nitrate phosphate fertilizers, urea, and other lumpy fertilizer materials.
2. Organic fertilizer industry: Crushing of fermented lumpy organic materials and recycled materials.
3. Chemical industry: Crushing of medium-hardness lumpy chemical raw materials.
4. Building materials and mining: Crushing of medium-hardness ores and building materials.
5. Environmental protection field: Treatment of organic waste from waste and sewage treatment plants. This equipment is particularly suitable for processing fertilizer materials with high moisture content, free acid, and high viscosity, and is an upgraded replacement for traditional vertical chain crushers.
Raw materials and scope of equipment
| Classification | Sub-field / Material Type | Applicable Material Description |
|---|---|---|
| Application Scope | Fertilizer Industry (Core) | Crushing of agglomerated compound fertilizer; crushing of bulk organic fertilizer and organic-inorganic compound fertilizer; crushing of unqualified returned materials; crushing of single superphosphate, triple superphosphate, phosphate fertilizer, ammonium phosphate nitrate and potash fertilizer. |
| Chemical Industry | Crushing of various chemical raw materials. | |
| Building Materials Industry | Crushing and processing of building material raw materials. | |
| Mining Industry | Crushing of medium-hard lump ores. | |
| Other Industries | Food raw materials, briquette processing; fibrous materials such as leaves, residues, bamboo chips, wood chips and waste paper; hard materials such as broken bricks, tiles, gravel and coal slag. | |
| Applicable Raw Materials | Organic Fertilizer Raw Materials | Livestock and poultry manure (pig manure, cow manure, chicken manure), industrial sludge, kitchen waste, biogas residue, mushroom residue, straw briquettes. |
| Chemical Fertilizer Raw Materials | Agglomerated compound fertilizer, single superphosphate, triple superphosphate, phosphate fertilizer, ammonium phosphate nitrate, potash fertilizer. | |
| Other Materials | Fibrous materials such as leaves, residues, broken bamboo, wood chips and waste paper; broken bricks, tiles, gravel, coal slag; medium-hard mining ores. | |
| Moisture Requirement | Horizontal model can handle phosphate fertilizer with moisture content of 14% and free citric acid of 6%; the whole machine is suitable for wet materials with moisture content ≤40%. |
Equipment Operation and Maintenance Methods
| No. | Fault Phenomenon | Main Causes | Solutions |
|---|---|---|---|
| 1 | Motor fails to run normally | Voltage too high or too low Motor phase loss Motor winding short circuit |
Restart after voltage stabilizes Check broken wiring to ensure three-phase operation Repair or replace the motor |
| 2 | Bearing overheating | Insufficient lubrication Damaged bearing Excessive machine vibration |
Fill lubricating oil Clean bearing and replace grease; replace bearing if necessary Overhaul machine and correct rotor balance |
| 3 | Excessive machine vibration | Uneven chain wear Rotor unbalance Loose anchor bolts |
Replace unevenly worn chains Correct rotor dynamic balance Tighten anchor bolts |
| 4 | Reduced output | Severely worn chains / hammer blades Uneven feeding Feed inlet blockage |
Replace worn chains / hammer blades Adjust feeding mechanism for uniform feeding Clear blockages at feed inlet |
| 5 | Coarser crushing particle size | Insufficient number of chains Chain abrasion Excessive clearance between hammer blades |
Increase quantity of chains Replace worn chains Adjust clearance between hammer blades and liner plates |
| 6 | Material sticking on housing | Excessively high material moisture Damaged liner plate inside housing |
Control moisture content of raw materials Replace or repair inner liner plate of housing Clean inner wall of housing regularly |
| Model | Input Particle(mm) | Output Particle(mm) | Power(kW) | Capcity(t/h) |
| LP500 | ≤60 | <Φ0.7 | 11 | 1-3 |
| LP600 | ≤60 | <Φ0.7 | 15 | 1-5 |
| LP800 | ≤60 | <Φ0.7 | 15 | 2-8 |
