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The roll compactor is designed to give you a low cost, mechanical means to upgrade or convert undesirable fines by agglomeration into a salable granular product. The roll compactor is also used for the agglomeration of fines into flakes for pyroprocessing… increasing product bulk density…and controlling the product solubility rate.

Ludman prestressed heavy duty frames minimize deflections and ensure maximum separating forces are transmitted to the product. The rolls of the roll compactor exert extremely high pressures on the fines as they pass through forming a solid ribbon of product with sufficient new character and strength. The product may then be further processed or granulated into a desirable particle size.

Costs saving features are many. Initial investment and operating costs are wholly consistent with the economies of recovery, and maintenance costs are low. The roll compactor can be integrated into your existing operation with little or no alteration. Costly feed preparations, such as inclusion of additives or binders, are rarely required and the process can be controlled by an operator with a minimum of technical training.

Rolls
Rolls are of one piece or two piece construction, shell on shaft, and of metallurgically evaluated wide variety of materials to meet the needs of theindustry.  The roll shells are centrifugally cast, heat treated of chrome and ductile iron composition and are mounted on alloy steel shafts. the shell/roll hardness on outside diameter is approximately 70 scleroscope, but can be varied, for a minimum depth of 1/2" on shell radius. This hardness depth allows for periodic regrinding and long roll life. Vapor blasting or equivalent of the rolls surface provides effective gripping surface at the point of nip.

Roll Bearings
The main roll bearings are of anti-friction type, double row spherical design with tapered bore. The roll shafts are drilled for hydraulic assist in mounting and removal of the bearings. The bearings are retained in heavy cast iron housing with double shaft seals of commercial lip type design for the inclusion of lubricant and exclusion of dust. The bearings are grease lubricated by fittings located at each bearing housing using bearing manufacturers W-33 lubrication feature. (Circulating oil lubrication is available upon request.)

Main Frame
The main frame, which supports the rolls and bearings, is constructed of a heavy plate weldment with replaceable steel bearing ways. Models 1208 and 2408 do not have replaceable bearing ways.

Roll Scrapers (optional)
Depending on the roll design and the application, each roll cound be provided with a steel scraper blade manually adjustable and rigidly mounted in a spring loaded holder. The blade and holder is mounted to the bearing housing, so scraper blade to roll contact is not effected by roll displacement. Blades are frame mounted on models 1208 and 2408.

Roll Separating Force
Compaction rolls separating forces are maintained by hydraulic pistons mounted in the front thrust bars. This separating force is restrained by alloy steel, full length tie rods which securely restrain the rolls under compacting pressures.

The available machine roll separating forces are from 100,000 lbs. (50,000 lbs. per bearing) up to 900,000 lbs. (450,000 lbs. per bearing) at a roll speed of 25-30 rpm. Reduced roll separating forces require only a reduction in hydraulic line pressure from the power pack. The hydraulic pressure is supplied by a separate hydraulic power package which can supply variable pressure to the compactor pistons. The machine pistons are single acting and roll gap adjustment is made by limiting the piston travel through a stud and nut arrangement at the piston cover. The maximum roll gap is 2" (1" piston travel and 1" of removable shim back of stationary roll bearing housing). Compacting pressure is generated only when feed material is passing between the rolls. Roll gap on model 1208 is maintained with a shim pack, on model 2408 with separate adjusting screws and locking device on rear thrust bar.

Hydraulic power package
A manually operated hydraulic power package is furnished for models 1208 and 2408. All other models are supplied with a motorized, hydraulic power package consisting of a reservoir, motorized high pressure hydraulic pump, filters, gauges, valves and accumulators for supplying variable pressure to the compactor hydraulic pistons. (Piping and all electrics between compactor pistons and hydraulic power package by purchaser.)

Roll side Cheeks
To retain the feed material at the roll ends, steel side cheeks are provided. The side cheeks are mounted on adjustable brackets which are supported from the tie rod bars. Separately mounted side cheeks are usable on both sides and easily replaced after long periods of wear.

Inlet Hopper
A short mild steel inlet hopper is machined and mounted. Adjustable seal bars and provided on the front and back of the hopper to conform to the roll diameters and serve as protection against pinching extraneous materials

Outlet Hopper
A mild steel outlet hopper is machined and mounted. Clearance is provided above hopper for sampling material discharge.

Paint Finish
Machine finish is grey epoxy paint over compatible orange primer coating.

Machine Drive
Compactor mills are usually driven by standard torque motors through specially designed double output shaft, parallel shaft gear reducers. Each reducer output shaft is connected by gear tooth high misalignment couplings to each compactor roll shaft. The drive is not a part of this specification since compactor horsepower varies with material to be processed and roll speed.

**If other type drive arrangement is desired, please consult factory for application.**

The standard compactor drive arrangement consists of the following four basic components:

Motor
A totally enclosed, fan cooled 3-phase, 60 cycle electric motor, with extended shaft for belted drive.

V-Belt
A high capacity V-belt drive furnished between the motor shaft and input shaft of the speed reducer. The drive is selected to provide approximately 1.4 service factor – also permits ease of revising roll speeds, by replacing sheaves as necessary.

Gear Reducer
A parallel shaft gear reducer having speed ratio to provide nominal roll speed of 25 rpm of the compactor. AGMA rated to provide operating service factor of 1.5 – output shafts are on centers equal to center of compactor rolls, designed to assume the full driving torque to the rolls.

Couplings
A pair of high misalignment gear couplings have induction hardened gear teeth – selected to permit up to 1-1/12" parallel misalignment in the high ratings (approximately 1-1/2" angular misalignment. Maximum flexibility in roll adjustment is permitted.

Roll Compactor Available Options

Main Drive
Hydraulic or Mechanical Drive System
Fixed Speed or Variable Speed Drive System
Single or Double Shaft Drives

Main Bearings
Babitted Journal Bearings
Spherical Roller Bearings

Main Rolls
One or Two Piece Rolls
Thru Handened Rolls
Welded Hard Faced Rolls
Chrome Plating or Nitride Roll Face
Custom Roll Corrugations
Water Cooled Rolls
Roll Speed Timing Coupling
Horizontal Roll Removal System

Product Feeder
Gravity Feeder – Gated or Non-Gated
Force Feeder – Single or Twin Screw

Design Accessories
Integrated Control Panels
Integrated Granulator or Roll Crusher
Stainless Steel Contact Surfaces
Custom Designed Work Platforms

Roll Pressure System (# of cylinders)
One per side
Two per side

Typical Material Applications
Ammonium Sulphate
Ashes
Burned Lime
Calcium Hypochlorite
Chrome Ore
Clay
Coal
Copper Concentrate
Detergents
Dried Sewage Sludge
FGD Gypsum
Filter Dusts
Herbicide
Iron Oxide
Magnesite
Magnesium Oxide
Metal Chips, Borings, Turnings
Mill Scale
Mixed Fertilizer
Muriate of Potash
Phosphate Rock
Potash Fines
Potassium Sulphate
Rock Salt
Salt
Sewage Sludge
Soda Ash
Sodium Chloride
Sodium Cyanide
Steelmill Residues