Crusher hammers
Mild steel hammers, changed through the side access door without dismantling the rotor. Inspect every 300 hours and turn the faces once the edges round off.
Fits6 per machine
Industrial Coal Disintegrator
Coal Crusher
Single Disc (5 No.)
Engineered for precision and consistency, this Single Disc Crusher effectively pulverizes coal into fine granules below 2mm. Featuring a robust 12mm body and 6 Mild Steel hammers, it is ideal for coke oven applications.
- Capacity
- 8 - 12 TPH
- Motor Power
- 80 - 120 HP
- Output Size
- < 2 mm
- Max Feed Size
- Up to 150mm
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What is a 5 No. single disc coal crusher?
A 5 No. single disc coal crusher is a coal disintegrator that reduces coal lumps of up to 150 mm to fine particles below 2 mm, the size needed for charging coke ovens and firing boilers. Inside a 12 mm fabricated steel body lined with manganese steel plates, a single rotating disc carries six mild steel hammers. Coal fed into the hopper is struck repeatedly by the hammers until it is fine enough to discharge.
The crusher is driven by an 80 to 120 HP electric motor, chosen to suit the output you need, and handles 8 to 12 tons of coal per hour. The hammers are replaced through a side access door, and routine care is limited to checking the liner plates and greasing the bearings. It suits coke oven plants and thermal power units with moderate throughput.
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.
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.
FitsSingle disc, 5 No.
Disc rotor with shaft
The balanced disc that carries the six hammers, fitted to a machined EN-8 shaft. Supplied as a complete assembly or as the bare disc.
FitsSingle disc, 5 No.
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.
Engineered for Tough Environments
The Manual Tools Company Single Disc Coal Crusher utilizes a unique high-speed impact action that is highly effective for reducing coal to specific sizes required for coke ovens and thermal power plants. The six hammers are mounted on one balanced disc, which gives controlled, uniform crushing and a consistent output below 2 mm.
Constructed with heavy-duty fabricated steel housing and lined with wear-resistant manganese steel plates, this machine is built for continuous, heavy-duty industrial operation.
Technical Parameters
| Parameter | Specification Value |
|---|---|
| Rotor Style | Single Disc (6 Mild Steel Hammers) |
| Motor Power | 80 HP – 120 HP (Based on required TPH) |
| Input Feed Size | < 150 mm |
| Output Size | < 2 mm (Fine Pulverization) |
| Crushing Capacity | 8 – 12 Tons Per Hour |
| Body Thickness | 12 mm Heavy-Duty Fabricated Steel |
3-Stage Operation Cycle
-
Step 01
Gravity Feed Intake
Raw coal lumps (up to 150mm) enter via the top hopper. The angled chute design ensures material is directed straight into the rotor's impact zone without clogging.
-
Step 02
High-Velocity Impact
The Single Disc rotates at 960-1440 RPM. Six suspended mild steel hammers strike the coal against the serrated liner plates, achieving instant size reduction.
-
Step 03
Calibrated Discharge
Crushed material passes through the bottom adjustable grate bars. Only particles smaller than 2mm are released onto the output conveyor, ensuring 100% uniformity.
Coke Oven Plants
Essential for preparing fine coal charge for beehive and recovery type ovens to ensure uniform combustion.
Thermal Power
Used for pulverizing coal for Fluidized Bed Combustion (FBC) boilers to maximize thermal efficiency.
Brick Kilns
Generates consistent fine coal dust required for automated kiln firing systems and mixture.
Maintenance Tip: Regular lubrication of the main bearing blocks extends machine life.
Daily / Weekly Checks
- Check foundation bolts for tightness before starting.
- Inspect V-Belts for proper tension and alignment.
- Ensure the crusher chamber is empty before motor startup.
- Monitor bearing temperature during operation (should not exceed 70°C).
Periodic Replacement
- Hammers: Inspect every 300 hours. Rotate faces if edges become rounded.
- Liner Plates: Check wear pattern monthly. Replace if thickness reduces by 60%.
- Rotor Disc: Inspect annually for any hairline cracks or imbalance.
- Bearings: Flush and replace grease completely every 6 months.
What is the output size?
The Single Disc Crusher is calibrated to produce a fine output size of below 2 mm.
What is the motor capacity?
It requires an electrical motor between 80 H.P. to 120 H.P. depending on your required TPH (Tons Per Hour).
Are the hammers replaceable?
Yes, the 6 Mild Steel hammers are designed for easy replacement via the side access door.
What is the delivery time?
Standard models are often in stock. Custom configurations typically take 3-4 weeks for fabrication.
What is the maintenance schedule?
Routine maintenance involves checking the liner plates and greasing the bearings. The hammers are easily replaceable when worn out.
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