What Is The Best Crusher
Selecting the appropriate crusher is crucial for any operation. Knowing the various stages of crushing and the types of crushers that best fit each stage simplifies equipment selection. Each type of crusher has its own characteristics and is used to produce a specific final result.
Similar to the previous stage Each crushing stage will be expected to produce a specific output for the following stage. Aggregate producers that match the right mill liners foundry with the appropriate stage will be the most efficient and, ultimately, most profitable.
Crushing stages
Aggregate producers are well-versed in selecting crushing equipment. They are aware that it is possible to select an equipment piece based on specifications and gradation calculations. It is nevertheless important to evaluate the theoretical implications against the practical experience with the material, as well as the maintenance, economic and operational features of different options.
In general, material reduction is handled in stages. There are a few single-crusher systems that are used, however the majority of systems have at minimum three or more crushing stages.
Primary crushing. The primary crusher is, above all, to make it possible to transport material on conveyor belts. Primary crushing in many aggregate crushing facilities is accomplished by using the jaw crusher. However it is possible that a gyratory primary crusher could also be employed. A crusher with an impact is an ideal choice for materials that are easy to crush and not too hard.
The most crucial aspects of a primary crusher is the capacity and capacity to take in raw materials without blockages. Larger primary crushers are more costly to purchase than smaller machines. This is the reason why the investment cost for primary crushers is assessed against the expense of blasting raw materials to a smaller size.
In the majority of cases, trucks transport the raw materials to a primary. The costs of maintenance, fuel, tires and the return on investment must be taken into consideration.
A pit-portable primary crusher can be an economically sound solution in cases where the producer is crushing at the quarry face. In modern plants it is usually advantageous to use a moveable primary crusher, so that it can follow the movements of the face where raw material is extracted.
Intermediate (secondary) crushing. The purpose of the intermediate crushing process is to create different smaller, coarser pieces or to prepare material for final crushing. If the intermediate crusher will be used to make railway ballast, it is essential to ensure the product's quality.
In other cases, there are no conditions for quality, but the product must be suitable to fine crush. In most cases, the objective is to obtain the greatest possible reduction at the lowest possible cost.
Fine (tertiary) crushing. In this crushing stage the quality and the quantity of fine products are determined. The final products are subject to stringent quality requirements, especially for the industry of aggregates.
In most cases, fine crushing and cubing functions are combined into one crushing stage. The choice of the appropriate crusher for tertiary crushing requires an understanding of the practical as well as theoretical know-how. In order to ensure the proper design of the system, the producers must consult an experienced application specialist.
Types of crushers
Jaw crushers
A jaw crusher is a compression type of crusher. Material is reduced by squeezing the material that feeds it between a moving piece steel and a stationary one. The discharge size is controlled through the setting or space between the two steel pieces. The setting is tighter, that results in less output and lower throughput capacity.
Jaw crushers are a type of compression crusher that produce the most coarse material. This is due to the fact that they crush rock with the natural lines of weakness. Jaw crushers are used as primary crushers in order to prepare the rock for further processing.
Cone and Gyratory Crushers
These machines also crush steel between two steel pieces. The setting between the two pieces determines the output.
Although the chamber is round in shape, the moving piece of steel isn't designed to move. Instead, the wedge is used to reduce one side of the chamber and discharge ports are made on the other. Cone crushers can be used in secondary and tertiary applications as an alternative to impact crushers when their shape is important however the percentage of fines generated must be kept to a minimum.
Impact crushers
Impact crushers utilize mass and velocity to decrease feed material. The feed material first gets diminished when it is placed in shredder parts, which rotates with the blow bars or hammers of the rotor. The secondary breakage occurs as the material is brought up into the stationary aprons , or breaking plates.
If the shape of the rock is crucial in determining the shape of a rock, impact crushers are frequently employed. Impact crushers crush rock along natural cleavage lines, resulting in higher quality products and shape.
Final thoughts
When selecting the crusher to best suit your operation it is crucial to comprehend your needs for each step.
During the primary phase, you should try to obtain materials to a size that your conveyors and other machines are able to handle.
Certain operations require further crushing during the secondary and third crushing phases. These stages help improve control and increase the size of the output.
Finding out how best to match the type of crusher to the correct crushing stage will guarantee the highest level of efficiency in your crushing operation , and ultimately increase your profitability.