Equipment Introduction
The horizontal crusher is a horizontally axially arranged continuous crushing equipment. Unlike vertical crushers, its main shaft is horizontally installed, and the overall structure has a flat layout, resulting in strong operational stability, low vibration, smooth feeding, and less clogging. The equipment is suitable for various dry and wet materials, offering excellent compatibility. It is a versatile core device for industrial pretreatment, material refinement, and solid waste resource utilization, widely replacing traditional vertical crushing equipment. It solves the pain points of vertical equipment such as wet material clogging, uneven output, and cumbersome maintenance, possessing core advantages such as high cost-effectiveness, simple operation, and low failure rate.
Equipment Structure and Components:
The equipment adopts an integrated precision structure, with core components including:
- Sealed quantitative feeding system: Variable frequency speed-regulating feeder for precise control of feed rate;
- Horizontal crushing chamber: All-stainless steel sealed cylinder, eliminating material residue dead zones;
- High-speed crushing rotor: Precision spindle, alloy crushing disc, and crushing gear ring, offering high wear resistance and precision;
- Variable frequency grading mechanism: Adjustable speed grading rotor for precise separation of coarse and fine materials;
- Airflow conveying system: High-pressure blower and duct assembly;
- Material collection system: Cyclone collector and pulse dust collector;
- Intelligent electrical control system: Variable frequency speed regulation, overload protection, and automatic temperature control module;
- Vibration-damping and noise-reducing base to minimize equipment operating deviations.
Applications of the equipment
| Application Industry | Processable Materials / Application Scenarios | Remarks |
|---|---|---|
| Organic Fertilizer & Bio‑organic Fertilizer Production | Chicken manure, pig manure, cattle manure, sheep manure and other livestock manure; straw waste, peat, mushroom residue; municipal solid waste compost, industrial organic waste | Core equipment for organic fertilizer production line, connects raw material collection and fermentation ripening process |
| Compound Fertilizer & Chemical Fertilizer Production | Blocky compound fertilizer, nitrogen fertilizer, phosphate fertilizer and other block chemical fertilizers; medium‑hard block materials; un‑dried calcium ammonium nitrate with moisture 14% and free acid 6% | Suitable for crushing block raw materials in chemical fertilizer production |
| Feed Processing | Corn, sorghum, oat, paddy, barley, soybean meal and other grains; pet feed and aquatic feed raw materials | Fit for large, medium and small‑scale farms and professional feed mills |
| Chemical & Pharmaceutical Industry | Foaming agent, carbon black, phenolic resin, surfactant and other chemical raw materials; pharmaceutical intermediates, pesticides, agricultural products; thermoplastic and fibrous materials | Meet crushing requirements of chemical and pharmaceutical raw materials |
| Minerals & New Materials | Inorganic salt, graphite, metal oxide, calcium carbonate, bentonite, talc and other non‑metallic minerals; lithium‑ion battery raw materials such as lithium cobalt oxide, lithium manganate, lithium iron phosphate and ternary materials | Suitable for processing non‑metallic minerals and lithium‑battery new materials |
| Other Industries | Wood blocks, bamboo, wood chips, straw, nut shells, herbal medicine; raw materials for building materials, food, plastic, rubber, metallurgy and ceramics | Strong universality, applicable for material crushing in multiple industries |
Working Principle of the Equipment
The equipment employs a dual-mode composite crushing principle, automatically adapting the operating mode according to the material: When processing fibrous or high-moisture materials, a high-speed hammer shearing mode is activated, with hammer linear speeds reaching 80-100 m/s, quickly cutting fibers and breaking up wet materials; when processing hard ores and slag, a toothed plate extrusion grinding mode is activated, crushing hard materials through high-strength toothed plate impact and extrusion. After entering the chamber, the material undergoes multiple impacts, shearing, and grinding processes to refine it. Qualified material quickly passes through the anti-clogging screen and is discharged. Large pieces of material are repeatedly crushed, ensuring continuous high-flow-rate operation throughout the entire process without the problem of wet material accumulation and clogging.
Raw Materials for the Equipment
The equipment is suitable for a wide range of conventional dry and wet mixed materials, including:
- Biomass materials: straw, branches, sawdust, rice husks, forage;
- Soft solid waste: fermented organic fertilizer, sludge, household waste, waste fabrics;
- Brittle materials: coal gangue, small ore pieces, gypsum, agglomerated chemical raw materials;
- Agricultural and by-product materials: medicinal herbs, agglomerated grains, fruit and vegetable residues. The equipment is suitable for raw material moisture content of 15%-25%, and can process semi-wet materials without easily causing adhesion and clogging.
Equipment operation and maintenance methods
| Module Category | Operation Stage | Key Operation & Maintenance Points |
|---|---|---|
| Installation & Commissioning | Foundation Installation | Place the machine horizontally on concrete foundation, fix with anchor bolts or welded supports to ensure stable and level body without tilt. |
| Installation Inspection | Tighten all bolts, lock main unit door, verify correct rotation direction of dual crushing shafts, reverse‑rotation is forbidden. | |
| No‑load Test Run | Clear foreign objects inside crushing chamber, run 1‑2 minutes without load. No abnormal noise, vibration or jamming before material feeding operation. | |
| Daily Operation Specification | Pre‑start Inspection | Check tightness of complete‑machine bolts; inspect chain bolts and pin shaft wear; confirm bearings have sufficient lubrication and good condition. |
| Running Process | Feed evenly and continuously, impact feeding is prohibited; hard objects and lumps over 150 mm are forbidden; do not open access doors or touch rotating parts during operation. | |
| Shutdown Operation | Stop feeding first, cut off power after all material is discharged; clean sticky and residual materials inside chamber timely to keep machine clean. | |
| Periodic Maintenance | Whole‑machine Patrol Check | Check and fasten loose bolts daily; inspect wear of chain connectors before shift, eliminate hidden faults in time. |
| Bearing Maintenance | Clean bearings and replace grease periodically, fill grease to 2/3 of bearing housing to guarantee smooth rotation. | |
| Wear‑part Replacement | Regularly inspect wear status of chains, hammers and blades. Replace worn, deformed or failed components promptly to guarantee crushing precision. | |
| Machine Cleaning & Maintenance | Clean sticky materials inside chamber daily; fully remove residual materials before long‑term shutdown to avoid corrosion and block‑caused component damage. |
Troubleshooting for Equipment Problems:
- Uneven particle size: Replace worn screens, adjust the gap between moving and stationary blades, and control the feeding speed evenly;
- Abnormal vibration and noise: Calibrate rotor dynamic balance, tighten machine body bolts, and replace worn bearings;
- Material blockage and shutdown: Stop the machine, clean the accumulated material in the chamber, reduce the material moisture content, and reduce the single feeding amount;
- Insufficient speed: Tension the drive belt, check motor power and wiring faults;
- Blade wear: Swap the working surfaces of the hammer blades, and replace those with excessive wear;
- Bearing overheating and abnormal noise: Add or replace lubricating oil, inspect bearing wear, and replace parts promptly;
- Electrical control faults: Check wiring, switches, and frequency converters, and troubleshoot short circuits and poor contact problems.
Equipment Applications in Production Lines
- Application in Organic Fertilizer Production Lines
The horizontal crusher is a core piece of equipment in the organic fertilizer production process, located between “raw material collection” and “fermentation and maturation.” Industry data shows that production lines equipped with horizontal crushers improve the uniformity of finished organic fertilizer by 40% and shorten the fermentation cycle by 15%.
Livestock and Poultry Manure Treatment: Crushes lumps (5-10cm in diameter) in manure to 1-2cm, increasing the contact area with microorganisms. A built-in magnetic separator adsorbs iron impurities, preventing damage to subsequent fermentation equipment. When processing chicken manure with a moisture content of 60%-70%, the hourly capacity can reach 5-10 tons.
Coarse Fiber Material Treatment: Crushes corn stalks to 3-5cm, disrupting the lignin structure and increasing microbial degradation efficiency by 30%. Compared to chain crushers, the blockage rate is reduced by 60% when processing straw mixed with soil.
Mixing and Conditioning: Utilizing a ribbon mixing structure, the material forms an up-and-down circulating convection within the cylinder, achieving a mixing uniformity (coefficient of variation) ≤5%.
- Integrated Crushing and Mixing Operation: This integrated crushing and mixing process saves 30% on equipment investment and reduces floor space by 20 square meters compared to the traditional “crush first, then mix” process.
- Application in Compound Fertilizer and Chemical Fertilizer Production Lines: The horizontal chain crusher is an indispensable advanced crushing equipment in the compound fertilizer industry. It is especially suitable for crushing various lumpy fertilizers and other medium-hardness materials. It effectively solves the long-standing problem of fertilizers being unable to be crushed due to moisture absorption, overcomes the disadvantage of materials sticking to the inner wall of the machine casing, and makes the crushing operation continuous.
- Application in Feed Production Lines: The horizontal crusher can be used for fine crushing in pet and aquatic feed processing, as well as coarse crushing in compound feed and flour processing. It is suitable for crushing feed for livestock and poultry such as pigs, cattle, sheep, rabbits, chickens, ducks, and geese.
