Crusher hammers
Mild steel hammers, reversed or replaced through the side access door. Inspect every 300 hours and turn the faces once the edges round off.
Fits12 per machine, 6 per disc
High Capacity Coal Disintegrator
Coal Crusher
Double Disc (5 No.)
Engineered for high-volume industrial demands, the Double Disc Crusher delivers superior throughput of up to 25 TPH. Featuring 12 Mild Steel hammers across two discs, it ensures rapid pulverization of larger coal lumps (<150mm) into fine <2mm granules for maximum combustion efficiency.
- Capacity
- 20 - 25 TPH
- Motor Power
- 150 - 180 HP
- Output Size
- < 2 mm
- Max Feed Size
- Up to 200mm
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- ISO 9001:2015
- Heavy Duty Series
- Global Shipping
What is a 5 No. double disc coal crusher?
A 5 No. double disc coal crusher is a high-capacity coal disintegrator for plants that need 20 to 25 tons of fine coal per hour. Two discs rotate together and carry 12 mild steel hammers in total, so coal is struck far more often than in a single disc machine. That lets it accept larger lumps, up to 200 mm, while still discharging coal below 2 mm through calibrated grate bars.
The housing is 16 mm fabricated steel, and each hammer can be replaced or reversed. A 150 to 180 HP slip-ring or squirrel cage motor drives the machine. It is built for large recovery-type coke ovens, bigger FBC boilers in thermal power plants and briquetting plants, and it handles coal with up to 8–10% moisture.
Spare and wear parts
We make the wear parts for every machine we build, to the same drawings as the machine, so a replacement fits without cutting or machining on site.
Twin disc rotor
Double disc rotor fitted with 12 mild steel hammers, on one machined shaft, balanced as a set so the machine runs true at speed.
FitsDouble disc, 5 No.
Manganese Steel Top Liner Jaw Plate
Jaw plates that line the crushing chamber and take the wear instead of the body. Bolted in, so a worn plate is swapped without cutting.
FitsDouble disc, 5 No.
Driving arrangement
Motor, gear box, flexible coupling and fabricated base frame, supplied as a matched set and aligned to the crusher shaft.
Fits150 - 180 HP drives
Also made to order: side liner plates, bearing housings, V-belt drives and hopper sections. Tell us the machine and we will quote the part.
Ordering a spare
- Name the machine, and roughly when it was supplied if it is ours.
- Send the old part's size, or a photo of it beside a tape measure.
- We quote the part, made to the same drawings as the machine.
Double the Power, Double the Output
The Manual Tools Company Double Disc Coal Crusher is the powerhouse of our pulverization line. By utilizing a dual-rotor configuration, this machine doubles the impact frequency, allowing it to process significantly larger feed materials (up to 150mm) while maintaining the ultra-fine output required for Coke Oven Plants.
Ideally suited for large-scale operations, the unit is constructed with a 16mm heavy-duty fabricated steel housing and features 12 replaceable Mild Steel hammers, with manganese steel liner plates to withstand abrasive Indian coal varieties.
Technical Parameters
| Parameter | Specification Value |
|---|---|
| Rotor Style | Double Disc (12 Mild Steel Hammers) |
| Motor Power | 150 HP – 180 HP (Heavy Duty) |
| Input Feed Size | < 200 mm |
| Output Size | < 2 mm (Fine Pulverization) |
| Crushing Capacity | 20 – 25 Tons Per Hour |
| Body Thickness | 16 mm Heavy-Duty Fabricated Steel |
High-Velocity Crushing Cycle
-
Step 01
Large Feed Intake
Capable of accepting larger lumps (200mm). The wide hopper throat ensures material distributes evenly across the width of both discs.
-
Step 02
Dual Rotor Impact
Two discs rotating in sync carry 12 Mild Steel Hammers. This creates a denser impact zone, pulverizing material faster than single-disc models.
-
Step 03
High Volume Discharge
The crushed coal passes through the calibrated grate bars. The doubled surface area allows for a massive 25 TPH discharge rate while keeping size < 2mm.
Large Coke Ovens
Designed for high-capacity recovery type ovens requiring continuous feed without downtime.
Thermal Power
Critical for larger FBC boilers where fuel consistency directly impacts megawatt output.
Briquetting Plants
Provides the massive volume of fine dust needed for industrial fuel briquette manufacturing.
Heavy Duty Note: Ensure the 160+ HP motor is soft-started to prevent belt slippage due to high torque.
Daily / Weekly Checks
- Check tightness of all 12 hammer bolts.
- Inspect main shaft bearings for vibration (heavy load zone).
- Verify V-Belt tension (dual grooves require precise alignment).
- Clear magnetic debris from the hopper to protect liners.
Periodic Replacement
- Hammers: Inspect 12 hammers every 200 hours due to higher throughput.
- Liner Plates: Rotate side liners to ensure even wear patterns.
- Bearings: Use high-temperature grease; purge monthly.
- Grate Bars: Check for widening gaps that might allow >2mm particles to pass.
How does this differ from the Single Disc model?
The Double Disc model uses two rotors and 12 hammers, doubling the capacity to 20-25 TPH and allowing for larger feed sizes (200mm) compared to the Single Disc's 8-12 TPH.
What motor is required?
Due to the high inertia and crushing load, a slip-ring or squirrel cage motor between 160 H.P. and 200 H.P. is required.
Can it handle wet coal?
It can handle moisture up to 8-10%. However, for very sticky or wet coal, we recommend cleaning the grate bars more frequently to prevent clogging.
Are the 12 hammers replaceable individually?
Yes, each hammer is individually suspended and can be replaced or reversed.
What is the delivery timeline?
Double Disc models are typically Made-to-Order. Fabrication usually takes 4-5 weeks depending on our current production queue.
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