Questions You Should Know about coarse crusher

Selecting a crusher for your quarry plant involves the consideration of a range of important factors, ensuring your investment will lead to increased efficiency, productivity, and safety.

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There are several key things you need to weigh up when selecting a fixed or mobile crusher, or crushers, for your new or established crushing operation.

&#;Some people familiar with the methods for selecting crushing equipment believe you can select a crusher purely based on calculations,&#; says Garth Taylor, MIMICO&#;s Material Processing Business Manager.

&#;However, theoretical assumptions should always be balanced by practical experience with different material, as well as with the operational, maintenance and economic aspects of the various options.&#;

1. What will I be feeding my crusher?

When selecting a crusher, understanding the characteristics of the material you intend to crush plays a significant role in crusher selection.

Materials can vary widely in terms of hardness, abrasiveness, moisture content, and the size and shape of the particles.

&#;Harder materials, like granite or basalt, are more challenging to crush and require a more robust machine,&#; says Taylor. &#;On the other hand, softer materials, like limestone, are easier to crush but can also have variable abrasion, potentially increasing wear on the crusher.&#;

Moisture content is another vital consideration. High moisture levels can cause clogging, reduce crushing efficiency and produce elevated wear. Additionally, the material&#;s density and the presence of contaminants like soil or clay can affect the crushing process.

The size of the feed material plays a significant role in crusher selection.

&#;Large, bulky materials require crushers with large feed openings and the capacity to handle high throughputs,&#; explains Taylor. &#;The nature of the feed material, whether it&#;s blasted rock, gravel, or recycled concrete, will also influence the choice of crusher.&#;

Blasted rock typically has a wide range of sizes, requiring a crusher that can handle oversized material while producing a consistent output size. Gravel or other alluvial deposits might need a different approach, possibly involving a combination of crushing and screening to achieve the desired product.

2. What product do I want to obtain?

Your desired end-product is a crucial factor in selecting the right crusher. The target product size and shape will dictate the type of crusher, and the crushing stages needed.

As an example, if the goal is to produce a fine aggregate for concrete, a vertical shaft impact (VSI) crusher might be the best choice, as it produces high-quality, cubical particles. On the other hand, if a more substantial, coarse product is needed for road construction, a jaw crusher followed by a cone crusher could be more appropriate.

Consideration of the desired product&#;s size distribution, shape, and quality is essential in making the right choice.

3. What are the strengths of each crusher type?

All crushers can be classified into two main types. Compressive crushers compress the material until it breaks, while impact crushers use the principle of quick impacts to crush the material.

&#;Jaw and cone crushers, along with gyratory and roller crushers, operate according to the compression principle, while impactors and hammer mills use the impact principle,&#; says Taylor.

The different types of crushers offer distinct features and benefits:

• Jaw crushers are known for their simple structure, high crushing ratio, and reliable performance, making them suitable for primary crushing of hard and abrasive materials.
• Cone crushers are ideal for secondary and tertiary crushing stages, providing high productivity and a high-quality final product.
• Impact crushers come in two types:
  • Horizontal shaft impactors (HSIs) offer high reduction ratios and are effective for producing coarse and fine aggregates.
  • Vertical shaft impactors (VSIs) offer excellent production of cubical particles and manufactured sand.
• Mobile crushers provide flexibility, allowing you to move the crushing operation closer to the source material, reducing transportation costs.

Each type has its advantages and limitations, making it essential to match the crusher to the specific needs of the operation.

4. What are my power requirements?

Power requirements are a critical consideration in crusher selection. Crushers are energy-intensive machines, and their power consumption can significantly impact operating costs. The power required depends on the crusher type, material characteristics, and the desired production capacity.

For example, jaw crushers typically require less power than impact crushers for the same material and capacity. Energy efficiency is an essential factor, as it directly affects the operational cost and environmental footprint of the crushing operation.

&#;A jaw crusher requires less power than an impact crusher for the same material and capacity,&#; says Taylor. &#;But, if we take this a step further and look at the energy required to produce a ton of product, the impactor may be more energy efficient, depending on product size required.&#;

Selecting a crusher with optimal power requirements that match the available power supply is vital for efficient and sustainable operation.

5. What is my total cost of ownership?

The total cost of ownership of a crusher includes not just the initial purchase price but also operating costs, maintenance expenses, and the cost of downtime. While a lower upfront cost might seem attractive, it could lead to higher operational costs if the crusher is inefficient or prone to frequent breakdowns.

It&#;s essential to consider the long-term costs associated with power consumption, wear parts, maintenance, and potential downtime. Investing in a high-quality crusher that offers reliability, energy efficiency, and durability can reduce the total cost of ownership, providing better value over the crusher&#;s lifetime.

&#;Additionally, the availability of spare parts and the manufacturer&#;s support network are important factors in ensuring minimal downtime and optimal performance,&#; suggests Taylor.

MIMICO holds an extensive selection of OEM parts for all the equipment brands the company works with, and are also specialist in indent parts supply for a range of makes and models.

Wear cost is a significant factor in the total cost of ownership of a crusher. Crushers operate in harsh environments and are subjected to constant wear and tear. The type of material being crushed, its abrasiveness, and the crusher&#;s design all have an impact on wear cost.

For instance, harder materials cause more wear on crusher parts, increasing maintenance frequency and replacement costs.

Advanced crusher designs and wear-resistant materials can help reduce wear costs, extending the life of the crusher and its components. Regular maintenance and using high-quality wear parts are essential strategies for minimising wear costs and ensuring the crusher operates efficiently over its lifespan.

Process simulation can help

The basic objective of crushing process planning is to be able to define a process that fulfils the end-product quality and quantity requirements reliably and economically. Software, including Bruno, a Metso tool available from MIMICO, will help inform this.

Bruno is an easy-to-use piece of software used for planning and simulating the crushing process. &#;With Bruno, you can quickly explore various machine combinations for certain applications or find out whether the existing machines are suitable for other applications,&#; says Taylor.

The core knowledge in Bruno is reliable modelling of unit machine based on extensive field test data from all types of crushers in various applications.

Do you need to process sand, gravel, minerals, rock, or other aggregate products and have not yet purchased or leased crushing equipment? There&#;s no question&#;you need to work with a capable and professional material handling equipment design and engineering company dedicated to selling, renting, and installing the best new crushers for your needs.

After all, our most recent Kemper Equipment success story illustrates what happens when an aggregate producer implements the wrong system design and material handling equipment!

However, if you&#;re new to the aggregate processing industry, you probably have a lot of questions about rock crushers. As foundational material handling equipment in all plants, crushers need to coordinate seamlessly with screens, conveyor systems, and washing equipment.

Today we&#;re breaking down everything you need to know about crushers to help you understand the questions you should ask as you search for the right material handling equipment for your operations.

For more information, please visit Jiangyin Chenyuan Machinery.

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Stages of Rock Crushing: Crushing Stations

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It is common to use multiple crusher types within a project and set them up as stations in a circuit format to perform the necessary material reduction work. In many cases, primary, secondary, and tertiary, and quaternary stations are installed to reduce the rock to the desired size, shape, and consistency.

Of course, not all projects require all the stations or stages. Sometimes, primary crushing alone may offer enough reduction for your needs.

For instance, if the final size of your product only needs to be between 4 inches and 6 inches, a primary jaw or impact crusher can accomplish your goals. However, you will likely require a much finer product, and that means incorporating up to three&#;or even four&#;stations with a variety of crusher types.

1. Primary Crushing

As the first stage in a crushing circuit following extraction from a mine site, (or in the case of recycled asphalt production, delivery to the RAP processing plant via truck transport), primary crushing reduces material to a size and shape that can be handled by the secondary crusher.

Typically, the minimum setting on most primary crushers will be about 4 to 6 inches, as noted above. Compression-style jaw, cone, impact crushers, and gyratory crushers are most often appropriate as primary crushing equipment types, though there can be overlap between primary and secondary crushers as far as suitable types.

2. Secondary Crushing

In secondary crushing, reduction ratios become an essential consideration. Knowing just how fine you need your final output to be, along with the feed requirements of your tertiary or final reduction crushing station, will help you determine how much reduction needs to take place within this stage.

Cone crushers are often placed within the secondary crushing station because they are versatile in terms of feed, closed side setting, speed, and throw. With cone crushers, though, it is essential to operate them at consistent choked settings  to keep productivity up.

3. Tertiary/Quaternary/Final Reduction Crushing

The goal of the tertiary (third), quaternary (fourth) or final reduction stage of the crushing process is to size and shape rock or other material into a marketable product. Again, there may be overlap between stages in terms of which crusher styles work best.

Cone crushers, vertical shaft impactors (VSIs), horizontal impact crushers, or even high-pressure grinding roll crushers may be used in the final reduction position.

Types of Rock Determine the Crushers You Need

Sandstone, limestone, gravel, and granite are arguably the most common aggregates used in the construction industry today, but these rocks have very different hardness and abrasiveness characteristics.

The type of rock you plan to focus on processing in your operation will dictate the types of rock crushers you&#;ll need to include in your crushing circuit.

The more you know about the type of rock you wish to crush and what its end-use will be, the easier it is to choose the best equipment to achieve your project goals.

So, How Many Types of Rock Crushers Are There?

The question &#;how many types of rock crushers are there?&#; can be answered in a variety of ways depending on what the person asking is trying to learn about rock, sand, gravel, or mineral processing.

The answer might be three to four if you&#;re talking about setting up stations in a complete rock crushing plant. Those are the primary, secondary, and tertiary/quaternary/final reduction rock crushers, which we covered above.

Of course, there are also different styles of rock crushers. Compression-style jaw and cone crushers, for example, fit into the various stations in a crushing circuit (depending on factors like the sizes, varieties, and hardness of the rock you need to crush, as well as the necessary output).

The number of crusher types in terms of style and configuration can be more challenging to quantify, as there are lots of ways to customize rock crushers. However, you&#;ll find four basic designs&#;cone, jaw, gyratory, and impact crushers&#;operating within many crushing plants.

Jaw Crushers

In compression crushing, jaw crushers tend to be more of a blunt instrument compared to cone crushers, which is why they&#;re often used in the primary rock crushing circuit stage.

Jaw crushers are also known as &#;rock breakers&#; and are used to break up larger, harder materials into more manageable pieces. They tend to do well with many different types of materials and don&#;t display as much wear and tear as impact-style rock crushers. They also produce minimal fine materials and dust, though the finished product with this type of rock crusher almost always requires secondary crushing.

To learn more about jaw crushers, you&#;ll want to catch our previous blog post all about these tough pieces of material handling equipment and the most common questions operators have about jaw crushers.

Gyratory Crushers

Gyratory crushers feature a conical head and concave surface (often lined with manganese steel) and break apart material by compression through what is known as eccentric movement.

Like jaw crushers, gyratory crushers are often utilized in primary crushing stations, though they may sometimes be used as secondary crushers, as well.

Cone Crushers

Similar to jaw and gyratory crushers, cone crushers work by compression, which means they reduce materials by squeezing them until they break apart.

There are also impact-style rock crushers&#;namely HSI and VSI equipment (more on those in a moment).

Cone crushers are built with a rotating mantle in a concave bowl lined with manganese&#;this is similar to gyratory crushers, but the crushing chamber in cone crushers is not as steeply angled.

Cone crushers can accept medium-hard to very hard and abrasive feeds that might be dry or wet, though not sticky (whereas gyratory crushers are better at handling softer, dryer feeds). Their output will be a relatively cubical product, with a reduction ratio of about 6-to-1 through 4-to-1.

Understanding the operating principle of cone crushing equipment is best illustrated in a visual format&#;check out this demonstration video from our Kemper Equipment YouTube channel.

Impact Crushers &#; VSIs and HSIs

Impact-style crushers include VSIs, as well as horizontal shaft impactors (HSIs), and are best used with less abrasive rock types, like limestone. These types of machines break apart material by the impacting forces of certain wear parts known as blow bars and impact plates or toggles.

Some operations also use impact-style crushers after they have already used a different type of rock crusher that produces a more elongated stone. This helps further shape the crushed material into a finer consistency with a more cubical nature.

Impact crushers tend to be less expensive than compression crushers (aka cone and jaw crushers, which we already covered) and have a higher reduction ratio. They can also break sedimentary deposit-type rocks&#;limestone and similar&#;along natural lines, which rounds off sharp angles and weak edges. This can produce a result that is more sand-like in nature.

Drawbacks of impact crushers include their tendency to produce an excess of fine materials if used with softer rocks. Impact rock crushers can also require frequent part changes and can create a large amount of dust that can be an issue on some worksites.

Portable vs. Stationary Crushing Plants

Depending on the length of your project and how mobile your crushing equipment needs to be, you can choose either stationary or portable/modular crushing plants.

Stationary plants have long been preferred because they feature a higher capacity and efficiency and lower production costs with easier maintenance. They also have historically featured a lower energy cost if you have on-site electricity, and no additional equipment is needed to move them from place to place.

The tides are beginning to change, though, and portable equipment has been technologically advancing to the point that it may be able to replace stationary plants in the future.

It&#;s true that portable material handling equipment already offers unmatched production flexibility. For instance, if you need to move your crushing plant more than once a year to multiple job sites, you are likely better off investing in portable equipment.

These self-contained plants are better suited to smaller projects and can be moved from project to project as necessary. They are often still not quite as efficient and have less capacity than stationary plants, but they can be more cost-effective in the long run if you have multiple projects in different areas.

Kemper Equipment Has the Crushers You Need for Your Operation

Still have questions about crushers or any other aspects of aggregate processing and material handling?

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