The selection of the right crusher is crucial for any process. Knowing the different phases of crushing and the different types of crushers that best fit the stage makes it easier to select the right equipment. Each crusher type has a different purpose and is designed to achieve a specific end result.
A Crusher Liners is the most common kind of maker utilized to minimize the size of rocks, or transform the type of waste to be certain that they can be easily disposed of or recycled for some objective. It may also be utilized to reduce the size of a mix of resources to distinguish items of different compositions. The enhanced mechanical advantage's pressure is utilized by the crusher manufacturers to crush the materials.
Similar to the stage before Each crushing stage is designed to generate a particular output for the next phase. Aggregate producers who match the correct mill liners foundry and the correct stage are the most efficient and consequently, the most profitable.
Crushing stages
The majority of aggregate producers are aware of the various options for crushing equipment and know it's possible to pick the right equipment solely on spec sheets or calculators of gradation. Still, theoretical conclusions must always be weighed against real-world experience of the materials at hand as well as of the operational, maintenance and financial aspects of various solutions.
In general, material reduction is usually handled in stages. While there are single crusher alternatives, the most well-known systems have at least two or more crushing stage.
Primary crushing. Primary crushing is the method used to make it possible to move material by means of conveyor belts. The primary crushing process in the majority of aggregate crushing plants is done with a jaw crusher. However it is possible that a gyratory primary crusher could also be employed. If material is easily crushed and not excessively abrasive, an impact breaker could also be the best option.
The main features of a mill liners foundry, are its capacity and ability to accept raw materials without any obstacles. Bigger primary crushers can be more expensive to purchase than smaller ones. This is why primary crusher investment costs are considered against the cost of reducing raw materials to smaller dimensions.
Most often, trucks transport raw materials to a primary. Also, you should take into consideration the cost of maintenance, fuel, and tires and the return on investment.
A pit-portable primary crusher can be an economically sound solution in the event that the producer is crushing on the quarry's face. Modern crushers usually benefit from the possibility of a mobile primary crusher that moves with the quarry face.
Intermediate (secondary) crushing. Intermediate crushing is used to produce coarser fractions and prepare the material for crushing. When the intermediate crusher will be used to produce railway ballast, product quality is important.
In other cases there are usually no quality standards, however the product has to be suitable for fine crushing. The objective is typically to reduce costs to the minimum and maximum reduction.
Fine crushing (tertiary). In this crushing phase the quality and the quantity of fine-quality products are established. The quality requirements may be strict for final products, especially in the aggregate industry.
In most cases, the fine crushing and cubicization processes are combined into one crushing stage. Experience in the field as well as theoretical knowledge are required when selecting a crusher to crush secondary materials. That's why producers must make sure they call an experienced specialist in applications to ensure that the system is properly engineered.
Types of crushers
Jaw crushers. Jaw crushers are a kind of compression crusher. Material is reduced by squeezing the feed material between a moving piece of steel and a stationary one. The setting or distance between two pieces of steel, controls the discharge size. The setting is tighter, which leads to an output that is smaller and a lesser throughput capacity.
As a compression crusher, jaw crushers generally produce the most coarse material since they break the rock by the natural inherent lines of weak points. Jaw crushers can be used as primary crushers to make the rock ready for processing later.
Cone crushers and gyratory crushers. They also have compression-type crushers that crush material between a moving and a stationary piece of steel. The output can be controlled through setting between the two pieces.
While the chamber is circular in form, the moving piece of steel is not intended to rotate. Instead the wedge is employed to reduce one side of the chamber, while openings for discharge are made on the other. Cone crushers are used for secondary and tertiary functions in lieu of impact crushers in cases where their shape is important however the percentage of fines produced needs to be reduced.
Impact crushers. Impact crushers make use of mass and velocity to decrease feed material. The first process is to decrease the material feed that is introduced into the crusher using the rotating blow bars as well as the hammers in rotor. Secondary breakage occurs when the material is forced into stationary aprons as well as breakers plates.
Impact crushers are typically utilized when shape is an important requirement and the feed material is not particularly abrasive. Impact crushers crush rocks along natural cleavage lines, which results in higher quality products and shape.
Final thoughts
In selecting the crusher to best suit your operation, it's important to understand your needs for each stage.
In the initial stage, you must get the material to a size that your conveyors can manage.
Some operations need further crushing in the secondary and tertiary crushing stages. These stages allow for more control over the amount and shape of the final product.
You can improve your crushing efficiency and profitability by matching the appropriate crusher to the appropriate stage.
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