Rotary Breakers: An Unsung Hero

The global coal industry continues to experience fluctuations in prices and demand. In 2024, coal consumption reached a record 8.77 billion t, with projections suggesting it will remain at this level through 2027.1

Efficiency and sustainability continue to be paramount in the coal industry. In that vein, rotary breakers continue to be an essential component of modern mining and processing operations. Renowned for their durability and low maintenance, they provide efficient sizing with minimal fines, while ensuring durability and optimal material handling.

Serving as both a primary crushing and cleaning system in run-of-mine (ROM) operations, rotary breakers efficiently fracture coal along natural fracture lines, while removing impurities, ensuring uniform sizing and enhancing overall product quality. By eliminating unwanted materials early, they reduce wear on downstream equipment, lower maintenance costs, and extend machinery lifespan. Their energy-efficient operation makes them a cost-effective alternative to more aggressive crushing methods, while also simplifying subsequent coal washing and processing steps. As demand for cleaner, higher-quality coal grows, rotary breakers play a crucial role in meeting environmental regulations and improving product efficiency.

Understanding how rotary breakers work

Rotary breakers operate on the principle of gravity impact, using a rotating drum to efficiently break down raw coal while simultaneously removing unwanted impurities, such as rock and shale. The process begins as ROM coal is fed into one end of the cylindrical drum, which is lined with perforated plates or grates. As the drum rotates, the coal is lifted and dropped repeatedly, creating a tumbling action that causes the softer coal to fracture. This ensures that properly sized material passes through the perforations, while oversized lumps continue to be recirculated until they are adequately reduced in size.

One of the key advantages of rotary breakers is their ability to separate impurities early in the process. The harder, non-coal materials – such as rock, shale, and tramp debris – fail to break down as easily as coal, and are carried toward the end of the drum where they are discharged separately. This early removal of contaminants improves the overall efficiency of coal processing, reducing the ash content and increasing the calorific value of the final product. By minimising unwanted material at an early stage, rotary breakers also reduce the wear and tear on downstream equipment, such as crushers, screens, and conveyor systems, leading to lower maintenance costs and extended machinery lifespan.

Furthermore, rotary breakers contribute to a more energy-efficient and cost-effective coal preparation process. Unlike more aggressive crushing methods, which generate excessive fines, rotary breakers produce a cleaner, more uniform coal product with minimal dust generation.

This helps simplify subsequent coal washing and processing steps, ensuring compliance with environmental regulations, and improving the overall quality of coal used in power generation and industrial applications. Their rugged construction, low maintenance requirements, and ability to handle high capacities make rotary breakers an essential piece of equipment in modern coal processing plants.

 

This is a preview of an article that was originally published in Issue 1 of World Coal 2025.

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