Crushers

The bulk crusher is a medium-sized horizontal crushing machine designed specifically for the fertilizer industry. It is primarily used to process single fertilizer materials with a moisture content below 40%, such as urea, and relatively high hardness. Its core structure utilizes two counter-rotating rollers, pulverizing the material through high-speed impact, extrusion, and grinding. The roller spacing is adjustable (3-12 mm) to control the output particle size (20-80 mesh), with a typical fineness range of 0.2-0.5 mm. The machine body is constructed of stainless steel or carbon steel and features anti-blocking toothed rollers and a sealed structure. It can be installed in either fixed or mobile configurations, offering dust-free operation, low energy consumption, and high crushing efficiency. Typical models include the TL75 series, with a processing capacity ranging from 2 to 15 tons/hour and a suitable motor power of 5.5-22 kW. It is suitable for high-nitrogen production in compound fertilizer plants, water-soluble fertilizers, and feed processing. Maintenance requires regular inspection of roller wear, cleaning of permanent magnet components, and lubrication of bearings. Abnormal vibration requires shutdown and repair.

After the installation and commissioning of the crusher is completed, before the operator takes over the production operation, he must carefully read the product manual, understand the structural principle of the crusher, be familiar with the performance and operating procedures of the crusher, operate it strictly in accordance with the operating procedures, and conduct patrol inspections in accordance with the operating procedures and precautions. While strictly following the operating procedures, you must also remember the following:
(1) The motor of the crusher is sealed with lead before leaving the factory, and the coupling has been calibrated. Please do not loosen it.

(2) Clean the iron impurities on the permanent magnet barrel and the permanent magnet plate of the crusher feeder regularly.

(3) Check the fineness of the crushed product regularly.

(4) Clean or replace the dust collector bag regularly (make sure the bag is breathable) and check the working condition of the solenoid valve regularly (to see if it can work normally).

(5) Check the wear of the various wearing parts of the crusher regularly to see if it is normal wear.

(6) Always pay attention to the vibration of the crusher.

(7) When the hammer of the crusher is seriously worn and needs to be replaced, pay attention to weighing to ensure that the two opposite (1800 direction) hammer pins on the opposite sides are The weight difference of each hammer is ≤1g and the total weight difference of the hammers on the two opposite (1800 direction) hammer pins is ≤2g;

(8) When the grinder screen is seriously worn and needs to be replaced, pay attention to the flatness of the new screen and whether the size of the screen is reasonable and whether it is installed in place. It is best to install it with the hair side facing inward;

(9) The opening degree of the impeller feeder air door should be adjusted appropriately;

(10) If the grinder is found to have abnormal conditions such as large vibration and high noise, it should be stopped and checked immediately;

(11) The main shaft bearing should be added with 80 grams of grease every 40 hours of operation, but only up to 60%. After 1800 hours of operation, the bearing box cover should be removed and all used grease should be replaced. When replacing with fresh grease, add grease to the area around the rollers and bearing rings, and add 1/3 to 1/2 of grease to the bottom box. Do not add too much grease.

(12) When the output of the crusher suddenly drops, in addition to the raw material factor, you should focus on checking whether the air supply door is in place, whether the pipeline is leaking, whether the pulse bag is blocked, and whether the solenoid valve and fan are working properly.

The single-shaft lump breaker is a De-agglomeration machine for crushing lumps and agglomerated bulk materials, widely applied in the fertilizer industry for processing hygroscopic and agglomeration-prone materials such as ammonium chloride, potassium fertilizer, and ammonium carbonate. During storage, these materials absorb moisture and undergo crystallization, which leads to the formation of large, hardened lumps that can significantly disrupt downstream conveying and granulation processes. To ensure smooth production, the lump breaker performs an initial coarse reduction, breaking down agglomerates—sometimes several centimeters in diameter—into smaller fragments typically below 30–40 mm. The machine operates with a low-speed rotor fitted with wear-resistant blades that rotate against a heavy-duty screen or grate, applying controlled impact and shear forces to achieve uniform particle size reduction. Its compact footprint, simplified mechanical design, and low specific energy consumption not only minimize maintenance requirements but also ensure stable throughput. In fertilizer plants, this makes the single-shaft lump breaker a reliable pre-treatment unit for preventing blockages, protecting downstream equipment, and maintaining consistent material flow across the entire production line.

Dual-rotor lump breakers are designed to process large, compacted, or crystallized materials by reducing them into smaller, free-flowing fragments through the combined mechanical actions of cutting, squeezing, and tearing. Equipped with two counter-rotating rotors fitted with sharp, wear-resistant teeth blades, the unit works in tandem with fixed breaker bars mounted inside the housing to apply continuous shearing and compressive forces. As raw feed materials—often several centimeters in diameter—enter the crushing chamber, they are gripped by the intermeshing rotors and progressively fractured until the particle size is reduced to typically less than 50 mm. This configuration is particularly advantageous for processing tough and compacted substances such as ammonium chloride, potassium chloride, ammonium sulfate, and multi-nutrient compound fertilizers, where consistent particle size reduction is critical to maintaining smooth conveying, mixing, and granulation downstream. The dual-rotor design offers high throughput capacity and superior reliability, as the synchronized low-speed, high-torque operation minimizes vibration, reduces dust generation, and ensures steady material flow even under heavy loads. Constructed with a robust housing, the breaker is engineered for continuous-duty industrial operation. The cutting knives are manufactured from high-strength, wear-resistant alloy steel, extending service life and minimizing replacement frequency. Its relatively simple mechanical layout reduces the need for intensive maintenance, while the heavy-duty bearings and precision-engineered drive system (typically Siemens or equivalent) enhance operational stability. Together, these features make the dual-rotor lump breaker a durable, efficient, and low-maintenance solution for fertilizer production lines, delivering reliable performance under demanding material conditions.

Selecting the right type of lump crusher requires a careful evaluation of both raw material properties and production requirements. The first factor to consider is the type of raw materials being processed. Fertilizer inputs such as ammonium chloride, potassium salts, or ammonium sulfate each exhibit different hardness, hygroscopicity, and agglomeration tendencies, which directly influence the selection of rotor design, blade material, and crushing chamber configuration. Equally important is the intended final product form—whether your production line aims to deliver finely powdered fertilizer or larger, free-flowing granules, as this will determine the necessary reduction ratio and screen or grate specifications.
Another critical parameter is the desired output capacity of the production line, since undersized crushers can become bottlenecks, while oversized units may result in unnecessary energy consumption and higher investment costs. Local environmental conditions must also be taken into account; factors such as ambient temperature, material moisture level, and the presence of humidity during storage strongly affect lump formation and dictate whether a single-shaft, dual-rotor, or cage-type breaker is more appropriate. In addition, the compatibility of the crusher with the upstream and downstream equipment—particularly drying units—is essential. Knowing whether the dryer relies on coal, gas, biomass, or waste heat recovery helps optimize crusher integration, as different heat sources influence moisture removal efficiency and the residual hardness of lumps.

Clumping is a persistent challenge in fertilizer manufacturing and is primarily influenced by three interrelated factors: moisture, temperature, and pressure. When fertilizers such as ammonium nitrate, urea, or NPK blends exhibit excessive residual moisture, the particles tend to absorb water vapor and undergo surface dissolution–recrystallization. This process causes adjacent granules to bond together, forming hard agglomerates. In many cases, high moisture levels are a sign of suboptimal performance in the drying system, whether due to insufficient residence time, uneven heat distribution, or improper airflow dynamics inside rotary or fluidized-bed dryers.

Temperature is another critical factor. Elevated post-drying temperatures soften fertilizer granules, increasing tackiness and making them more susceptible to bridging or adhesion in storage silos. To mitigate this, cooling equipment—such as rotary coolers or fluidized-bed coolers—is integrated downstream of the dryer, reducing product temperature close to ambient levels to stabilize granules and maintain free-flowing properties.

Pressure within the production line also plays a role. High compaction forces during granulation or conveying can deform particles, increasing their surface area and exposing reactive sites. This not only heightens the likelihood of mechanical bonding but can also accelerate chemical reactions, particularly in fertilizers containing ammonium salts, which are prone to caking under stress.
Effectively managing these parameters—by optimizing dryer performance, incorporating efficient cooling stages, and maintaining controlled pressure conditions—is essential to minimizing clumping. Doing so not only improves product quality and storage stability but also ensures consistent flow, reduced downtime, and extended equipment life throughout the fertilizer production process.

Lump crushers operate by feeding agglomerated or compacted materials into the crushing chamber through an inlet at the top of the unit. Inside, oversized particles are subjected to mechanical impact, shearing, and compression as they pass between rotating blades and a set of stationary comb-like breaker bars. The intermeshing action of the rotating and fixed elements progressively fractures the lumps, reducing their size in a controlled manner. Material continues to circulate and break down until the particle size is sufficiently small to pass through the discharge openings at the bottom of the crusher, ensuring uniform output.

These units are particularly effective for deliberately compacted materials or naturally agglomerated products, which commonly occur during production, storage, or transportation. By effectively breaking down such lumps, the crusher not only facilitates smooth downstream handling and processing but also protects conveyors, feeders, and granulation equipment from blockages or mechanical strain. The controlled crushing action, combined with heavy-duty rotor construction and wear-resistant blades, ensures consistent throughput, minimal dust generation, and long-term operational reliability in fertilizer production lines.

Selecting the right crusher type depends on the target particle size of the material and the metric used—microns (µm), millimeters (mm), inches, or mesh. Each crusher is optimized for specific size ranges and material characteristics.

Lump Breakers are designed for coarse pre-crushing of agglomerated or caked materials. They typically reduce lumps from 30–150 mm down to 5–40 mm, suitable for ammonium chloride, urea, and compound fertilizers. In mesh terms, this corresponds roughly to 5–3 mesh, and in microns, approximately 5000–40,000 µm.

Cage Crushers provide secondary crushing to achieve finer particle sizes. They typically reduce material from 20–50 mm down to 1–10 mm, corresponding to 2–16 mesh, or approximately 1000–10,000 µm. This makes cage crushers suitable for producing uniform granules for blending or downstream processing.

Chain Crushers are heavy-duty crushers that handle hard, compacted materials. They can reduce raw material from 50–200 mm down to 10–30 mm, which is roughly 0.4–1.2 inches or 0.5–2 mesh, depending on rotor settings and material hardness. Chain crushers are ideal for high-moisture, high-density fertilizers requiring robust size reduction.

Lump breakers are versatile units that can be seamlessly integrated into various points within a fertilizer production and handling system to ensure smooth material flow and prevent blockages. System integration is critical for maximizing operational efficiency, and the units can be positioned in multiple stages depending on process requirements.

One common application is delumping prior to pre-bag loading, where large agglomerates formed during storage are broken down to ensure uniform filling and prevent bridging in packaging lines. Another key scenario is delumping before granulation, which ensures that coarse clumps do not enter the granulator, maintaining consistent particle size and protecting downstream equipment from excessive wear.

Lump breakers are also applied after bin unloading, reducing compacted or naturally agglomerated materials before feeding into conveyors or mixers, and after bag unloading, where materials that may have hardened during transport are restored to a free-flowing state.
By strategically placing lump breakers at these critical points—pre-bag loading, pre-granulation, post-bin unloading, and post-bag unloading—fertilizer manufacturers can maintain continuous, reliable operations, minimize downtime, and achieve consistent product quality. Integrating robust units such as Prater Lump Breakers and Flake Breakers ensures precise particle reduction while accommodating a wide range of fertilizer types, moisture levels, and operational conditions.

Tongli Lump Breakers and Flake Breakers are designed with a focus on durability, efficiency, and adaptability, meeting the demanding requirements of fertilizer and bulk material processing. Their heavy-duty construction ensures a long service life, even under continuous operation with abrasive or high-density materials. Units are available in mild steel or stainless steel, allowing selection based on material compatibility, corrosion resistance, or sanitary requirements.

The design prioritizes easy installation and maintenance, featuring externally mounted bearings with optional air-purge seals to reduce contamination and extend bearing life. Internal components, including blades and screens, are easily replaceable, and a wide variety of blade designs can be selected to match specific materials and crushing requirements. Customizable screen sizes allow precise control over output particle size, while drive systems—V-belt, cogged belt, or direct drive—provide flexibility to suit different plant configurations.

The low-profile design allows installation in tight spaces, and optional features such as wear liners, wear-resistant blades, and quick-clean mechanisms help minimize downtime and maximize productivity. For applications with high sanitation requirements, models with sanitary construction are available. Units can also be fully integrated with bag-dump workstations or bulk bag unloading systems.

Tongli lump breakers are offered in both single- and dual-shaft configurations, delivering superior delumping performance across a range of materials—from lightly caked powders to heavily compacted granules. Together, these design features ensure optimized product handling, consistent particle size reduction, and reliable operation, making Tongli Lump Breakers and Flake Breakers a versatile and dependable solution for modern fertilizer production lines and bulk material handling systems.

Tongli Single-Shaft Lump Breakers (also called Flake Breakers) offer a simple, durable, and cost-effective solution for handling materials that become compacted or lumpy during storage, transport, or blending. By applying gentle impact and shear forces simultaneously, these machines break up lumps and produce free-flowing materials with uniform particle size, which is essential for efficient conveying, blending, and packaging in many industries. The result is improved product quality, reduced downtime, and lower operating costs.

Tongli Dual-Shaft Flake Breakers provide the same benefits as single-shaft models but in a low-profile design, making them suitable for installations with limited space. Equipped with counter-rotating blades, they are ideal for conditioning or granulating materials that have been purposely compacted in densification equipment, as well as for recycling or disposal operations.

These precision machines are effective for a wide range of products, including: fertilizers, sugar, salt, resins, pigments, pasta, nutraceuticals, minerals, kiln dust, hemp, filter cakes, chemicals, cereals, and ceramic powders. The robust construction, wear-resistant blades, and customizable screen sizes allow them to handle both high-density and hygroscopic materials reliably, ensuring consistent output and smooth operation across production lines.

In short to reduce agglomerates and compacted materials to suitable particle sizes and flowability for downstream mixing and granulation processes in npk compound fertilizer production line and organic cow dung manure fertilizer plant.

The Tongli TL75 Silo Lump Breaker is a robust, low-profile unit designed to reduce compacted, lumpy, or agglomerated materials stored in silos, bulk bags, or handheld sacks back to their original particle size and flowability. While it serves a similar purpose to a fertilizer lump breaker—ensuring smooth material flow and preventing blockages—it is engineered specifically for inline mounting in restricted spaces, such as between upstream outlets and downstream inlets of process equipment. So the conclusion is these two machine are similar but the blades are different as well as the motor power, also differs in structure.

The TL75 features a compact, low-profile design with matching inlet and outlet flanges, allowing seamless integration into production lines. It is available in stand-alone configurations with hopper and support stand, and its construction accommodates both light-duty and ultra-heavy-duty applications. Material reduction is achieved through the interaction of single or multiple rotors (1 to 4 rotors) with stationary combs or dual rotor setups. Lumps are forced against each other or against the combs until the material reaches the desired particle size, as determined by bed screen perforations.

The unit operates at low RPM, minimizing heat generation and ensuring gentle handling, even for heat-sensitive or hygroscopic materials. Drives range from single 3 hp (2.2 kW) motors to dual redundant 20+ hp (14.9+ kW) motors, with chain and sprocket systems providing high-load durability without the slippage or wear issues associated with belts or intermeshing gears. External lubrication access eliminates the need to remove guarding during routine maintenance, while optional side-access screens allow rapid, tool-free cleaning, inspection, or screen changeover. The one-piece lump-breaking weldment can also be easily replaced as an integral unit.

Constructed with AR-235 abrasion-resistant steel for standard models, the TL75 can also be built in #304 or #316 stainless steel to meet pharmaceutical, food, or industrial standards. The dual-drive configuration on larger models not only increases capacity and power but provides redundancy, preventing material backflow in case of a drive or power failure.

Typical applications include fertilizers, agglomerated sugars and salts, sodium/calcium carbonates, chemicals, cement powders, flakes, and other hygroscopic or compacted industrial products. With its heavy-duty construction, precision rotor design, and versatile mounting options, the TL75 ensures consistent particle size, free-flowing material, and reliable operation throughout the production and conveying process.

Tongli Lump Breakers can handle a wide range of materials that tend to form lumps or clumps during storage, transport, or processing. They are commonly used for fertilizers such as salts, potash, phosphate rock, MAP (Monoammonium Phosphate), and DAP (Diammonium Phosphate). They also work well with organic materials like straw, manure, and compost.

In addition, Tongli Lump Breakers are suitable for sugar, salt, resins, pigments, minerals, kiln dust, filter cakes, chemicals, cereals, hemp, and ceramic powders. These machines can break down large, compacted particles into smaller, free-flowing sizes, making them easier to handle, mix, convey, or package.

With strong blades, adjustable screens, and robust construction, Tongli Lump Breakers ensure consistent particle size, smooth material flow, and reliable performance for a wide variety of industrial and agricultural materials.