Powerful, efficient, and intelligent: Christian Pfeiffer launches the new ROP roller press
Christian Pfeiffer introduces its latest roller press (ROP), delivering state-of-the-art technology and exceptional reliability for demanding comminution processes. The ROP is engineered specifically for raw material processing, seamlessly integrating advanced technical features with a technology-driven design.
Powerful components and high flexibility
Christian Pfeiffer provides a comprehensive performance package that includes all components necessary for smooth installation and long-term operation. This package includes a robust pre-Bin with a capacity of up to 90 seconds of material feed, shut-off gates, an intelligently designed feed chute with dual gates for precise material flow control, and specially hardened rollers with a unique layered structure engineered to handle extreme loads.
For easy maintenance, the ROP is equipped with a maintenance platform, and unique maintenance solutions ensure reliable long-term operation, even under challenging conditions. Additionally, Christian Pfeiffer offers various drive options to meet different voltage and frequency requirements, including variable-speed low-voltage motors (400/690V) or variable-speed medium-voltage motors (4.16/6.0/6.6 kV), each designed to maximize the ROP’s efficiency.
ROP – Innovations in crushing technology: Key features
1. Pre-bin system for optimized material feed
Mounted on the plant’s steel structure, the pre-bin ensures a constant material feed, with the fill level monitored by precise load cells in combination with the innovative feed chute. This setup guarantees a steady comminution process without material shortages, improving process stability and productivity.
2. Precise control of material feed
Christian Pfeiffer’s roller press feed chute is equipped with two pairs of gates to regulate the material flow, allowing operators to adjust the comminution process in real-time. An integrated dedusting system removes excess air and dust, minimizing process fluctuations and maintaining a clean working environment.
3. Rollers with innovative layered structure for maximum service life
The specially developed rollers consist of two components: a robust shaft and a shrink-fitted roller. The wear protection of the rollers is structured in three layers: a buffer layer to prevent cracking, a hardness layer for strength, and a profiling layer to minimize wear from abrasive forces. This structure allows for a service life of up to 100000 h without welding repairs, depending on the ROP’s application. Maintenance on the roller surface wear protection can be performed directly on the machine, reducing maintenance costs.
4. Rollers with ceramic wear protection for ore grinding
These specially designed rollers consist of a robust shaft and a shrink-fitted sleeve. Wear protection is ensured through ceramic inserts, achieving a service life of up to 10000 h, depending on the ROP’s application. Maintenance of the ceramic wear protection is performed with the rollers removed, requiring a second set of rollers to be kept on stock for continued processing. The ROP’s design allows for a quick and seamless roller pair exchange.
5. Advanced bearing design for maximum operational safety
ROP models with a pressing force of approximately 9000kN or higher are equipped with cylindrical roller bearings. Specialized guide elements in the bearing housings compensate for roller skewing, ensuring precise axial alignment of the rollers. Smaller ROP models are fitted with self-aligning bearings, reducing space requirements and costs. A revolutionary axial guidance system with chrome-plated guide rails and Teflon sliding surfaces facilitates maintenance and minimizes operational interruptions.
6. Oil circulation lubrication system for longer service life and efficient cooling
An integrated oil circulation system continuously filters the lubricant oil, removing contaminants to extend bearing life. The circulating oil effectively dissipates the heat generated during the comminution process, eliminating the need for additional cooling bores in the roller shaft.
7. Cheek plates for durable protection and easy maintenance
The lateral roller surfaces are enclosed with cheeks plates featuring wear protection. These cheek plates are flexibly mounted, adapting to roller movements and alignment to provide consistent lateral sealing. The design en-ables easy removal of the cheek plates without requiring additional cover dismantling.
8. Stable machine frame design with maintenance friendliness at the core
Christian Pfeiffer designed the ROP frame to deliver high stability with reduced weight and maximum user-friendliness. Large openings in the frame facilitate inspection of critical components, enabling early wear detection and timely maintenance planning.
Powerful hydraulics and precise drive technology
The ROP is equipped with a hydraulic pressure system that transfers the necessary pressing force to the movable roller through two hydraulic cylinders. These cylinders are mounted on pivot bearings to flexibly follow the movements of the roller.
The drive of the ROP is based on a powerful system with planetary gears and safety couplings designed for reli-able torque transmission. The drive is protected by a safety coupling that regulates the inertial torque during load changes and prevents overloads. Additionally, a driveshaft provides the necessary flexibility, ensuring that the motor remains free of load, and the machine is easily accessible for maintenance. Optionally, a hydraulic coupling can be chosen for quick and maintenance-friendly installation.
Intelligent control and monitoring technology
Thanks to an advanced control system, the ROP is almost fully automatic. The control system handles a variety of complex monitoring and control tasks and responds to changes in material flow.
The main functions include:
Monitoring of All Sensors
Automatic Pressure and Gap Control using two-way cylinders
Feed chute control
Misalignment Monitoring of the Movable Roller
Master-Slave Control for torque and speed management
Level Monitoring of the pre-bin
Temperature Monitoring of bearings and gears
Vibration Monitoring for preventive maintenance
The control system can be integrated either as a standalone system or as a software component into the existing plant control system, allowing for flexible adaptation to the customer‘s requirements.
Special tools for efficient maintenance
For safe and efficient maintenance, Christian Pfeiffer provides a selection of specialized tools, including lifting tools and transport devices for the rollers incl. bearings, gauges for wear measurement, and transport equipment for hydraulic cylinders. These tools ensure safe handling and significantly facilitate maintenance work, resulting in increased uptime and thus higher availability of the plant.
Conclusion: High performance and efficiency in industrial crushing
Christian Pfeiffer’s new ROP roller press sets benchmarks in industrial comminution technology. With a strong focus on durability, ease of maintenance, and intelligent control, it offers a solution suitable for a wide range of industrial applications and can be flexibly adapted to the specific requirements of customers.
