Together
to success
since 1997
"INTECH GmbH"
We are interested in cooperation with the manufacturers of roll crushers, who are looking for an official and reliable distributor to deal with supply & delivery of their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your roll crushers. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative in Russia, our marketing staff will carry out a market research in order to check the demand for roll crushers, will submit a market overview for roll crushers that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your roll crushers and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods, for various types of roll crushers in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for roll crushers as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your roll crushers into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of roll crushers. They will also provide necessary training and guidance for the customer’s personnel.
The rolls grind material by crushing it, by continuously pressing the ground pieces. Crusher rolls composed of welded frame and two cylindrical rollers equal by diameter. Rolls are located on horizontal axles and are counter-rotating.
Material fallen from above on the rolls are drawn into the gap between rolls by friction force. It is gradually ground there and discharged from the crusher as small grains of a particular size. Grinding degree vary with the gap between rolls.
Crusher rolls crush materials without abrasion because of the constant width gap between rolls. Particles smaller than the gap freely pass without an excessive amount of fine material.
One of axles is fixed and another is located in moveable bearings in order to prevent rolls deformation and breakage when entering too large and solid material pieces into them. When entering a large material piece, a movable axle moves aside over a distance sufficient for this piece travel, whereat it moves closer to the fixed axle by a special spring. Crusher rolls' springs may produce a pressure up to 5000 kgf/cm2.
For charged material grinding by rolls its pieces should be retracted into the gap between rolls rotating towards each other. Material pieces retraction into the gap depends directly on rolls nip angle, i.e. angle between material contact points with crusher rolls surface.
Nip angle size depends directly on pieces size, rolls diameter and material friction coefficient. As for jaw crushers discussed above, rolls nip angle must not exceed a double friction angle, i.e. be more than 34 degrees.
A nip angle becomes smaller while increasing the rolls diameter and space between them as well as while reducing material pieces size.
When considering rolls diameter and size of material pieces subjected to grinding, there is some relation between them, namely:
R = r/(1-cos[φ/2])
Where:
R – ground material pieces radius;
r – crusher rolls radius;
φ – nip angle.
In practice, the following rolls diameter (D) is taken: D = (20 ÷ 25) d, where d - a diameter of ground material pieces.
Hence, it follows that crusher rolls are mainly used for medium and fine crushing. However, slugging or fluted rollers can grind much bigger material pieces. For slugging rolls D = (2 ÷ 5) d, and for fluted D = (10 ÷ 12) d.
Crusher rollers diameter can range from 230 to 1500 mm.
Performance and power consumption
Maximum crusher rolls performance is directly proportional to the volume of material strap, which goes through the gap between rolls.
Material volume (V) coming into the gap between rolls is equal to:
Vsec = Fω = beω, cm3/sec
Where:
ω – rolls rotation speed, cm/sec;
b – rolls length, cm;
e – gap size between two rolls, cm.
Two cylindrical rolls are installed on the welded frame in parallel each other. One roll locates on the sliding bearings (movable) and another roll rotates on non-movable bearings (fixed).
Movable roll is retained against the fixed one via cylindrical (in some cases band) springs mounted directly behind the fixed bearing. Springs pressure on the movable roll is transferred by locking screw and special faceplate.
Crusher rollers are equipped with V-belt drive and have roll gear drive. Gear drive is used for those rolls, periphery speed of which is not more than 3 - 4 meters per second during operation. However, gear drive has two major drawbacks: its teeth often break and it generates a noise during operation. High-speed mills' rolls have their own, independent belt drive.
Because movable roll travel is back-and-forth, the quite large inertia forces, which inevitably transmitted to mill foundation, occur during operation. In order to balance inertial forces and, consequently, balance crusher rolls operation, the rolls of some machine designs, which travel in opposite directions, are movable.
The rolls can be fixed. Such machines perform a uniform crushing and operate with virtually no vibration. Although they are cheaper than spring rolls, they are less reliable and inefficient. A special magnetic separator is installed over their feeder in order to prevent fast breakage of these rolls from accidental ingress into metallic pieces into them.
As a rule, roll consists of two parts - inner and outer. Its inner part is a core typically made of cast iron. Roll crushing outer part is a demountable thread band made of hard, wear-resistant steel or chilled cast iron. Roll core is a cone disk with a sleeve with cone rings put on it and reliably screwed up with a disk providing very tight thread band fixing.
For crusher rolls stable operation, regardless of their design, there must be provided a continuous and uniform material charging. As a rule, a special tray feeder is installed directly above the rollers.
Basic working elements of roll crusher are two counter rotating rolls, which can be equipped with jaws or teeth. Large material pieces feeding from above are captured by jaws and crushed passing between them. At smaller rotation speed, crushing takes place mainly due to compression and friction while at greater rotation speed crushing mainly takes place due to impulse loads.
Due to the fact that one roll of a crusher can be displaced, you can change the gap width between rolls, which allows changing final product grains size.
Roll crushers are used for limestone, salt, chalk, chamotte and other materials with a moderate hardness. The advantages of such devices are compactness and reliability.
Toothed or fluted rolls operate directly by trapping the material pieces. Toothed roll crushers are able to trap even very large pieces where diameter of which is equal to 1/2 and even 2/3 of roll diameter. Because rolls teeth crush the pieces via cracking, these machines are used for crushing the most fragile materials such as coke, limestone, phosphate rocks, salt and other non-metallic mineral deposits.
Sometimes, roll crushers are two-levelled. Material pieces in such machines are firstly crushed by toothed rolls located above and then by smooth rollers located below.
Three-rolls ring mill is a crushing ring that stands vertically and rotates freely. The ring is made of solid steel grades. Three steel rolls are retained by springs against the ring, to its inner surface.
Upper roll is leading and it is driven by transmission. Due to friction force, this roll drives the ring, which transmits the motion to the rest 2 rolls. Both lower rolls retained against steel ring by springs. Material flows along the chute into ring and then it is crushed between the ring and rolls. Ring continuously rotates delaying the material on it and transporting it past other rolls. Material is crushed under pressure, which can be adjusted with springs.
While falling from the ring after grinding the material leaves through the bottom mill hole. While pressing together a thick material layer is collected between ring and rolls preventing their contact. By means of it, the mill can operate quietly and ring and rolls not wear quickly despite the constant mobility during operation. Ring and rolls have a spring support, which allows taking up shocks and blows with ease by changing position.
Such mills performance depends on ground material and its grinding fineness. Pieces fed for grinding should not be more than 30 mm in size. The performance of such mills for average grinding fineness is within 3,000 – 9,000 kg per hour.
Other equipment
Upon becoming the official distributer of agitators (mixing equipment), our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (agitators (mixing equipment)) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!
