Enhancing Coal Crusher Performance through Understanding the Operating Principles

Coal crushers are important equipment in coal-fired power plants. The crushers pulverize the coal into a fine powder to facilitate combustion and increase overall plant efficiency. Coal crushers also known as coal pulverizers or coal mills are mechanical devices that crush coal particles, primarily used in the power generation industry.

Understanding the operating principles of coal crushers is essential for maintaining the equipment's performance. This article discusses the principles and provides tips to enhance coal crusher performance.

The Operating Principles of Coal Crushers:

1. Crushing Process: - The coal enters the crusher through a centrally located inlet valve. - The coal is crushed between two rotating plates, hammers, or anvils. - The larger coal particles are caught between the upper and lower crushing surfaces. - The crushed coal particles are discharged through the outlet valve.

2. Primary and Secondary Crushers: - Primary crushers are used to reduce large coal particles into smaller particles. - Secondary crushers further reduce the size of the crushed coal. - Primary and secondary crushers work together to achieve the desired coal particle size for combustion.

Tips to Enhance Coal Crusher Performance:

1. Regular Maintenance: - Regularly inspect the crusher and its components for wear and damage. - Check for proper lubrication of the bearings and gears. - Replace worn-out parts promptly to avoid unexpected breakdowns.

2. Proper Alignment: - Ensure the crusher rotor and hammers are aligned correctly. - Misalignment can cause uneven wear on the crusher components, reducing performance and increasing maintenance requirements.

3. Optimal Hammer Design: - Select the appropriate hammer design based on the coal properties and desired particle size. - Different hammer designs are available, including rigid hammers, swing hammers, and combination hammers. - The hammer design influences the efficiency and effectiveness of coal crushing.

4. Controlled Feed Rate: - Maintain a steady and controlled feed rate into the crusher. - Avoid overloading the crusher with excessive coal feed, which can cause blockages and decrease productivity. - Use feeders or other equipment to control the coal feed into the crusher.

5. Particle Size Control: - Monitor and control the coal particle size distribution. - Optimal particle size distribution ensures efficient combustion and reduces emissions. - Use sieves or screens to control the coal particle size before and after crushing.


Understanding the operating principles and following the tips mentioned above can enhance the performance of coal crushers in power plants. Regular maintenance, proper alignment, optimal hammer design, controlled feed rate, and particle size control are critical factors to achieve reliable and efficient coal crushing. Implementing these practices can result in improved plant performance, reduced downtime, and increased overall coal crusher efficiency.

Contact us