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The Right Crusher For You



crusher



It is vital to select the correct crusher for each task. Knowing the various stages of crushing and the different types of crushers that are best suited to each stage simplifies equipment selection. Each type of crusher has its own characteristics and is used to get a particular end result.


Similarly, a certain output is expected to be produced at the end of each crushing stage for the next stage of the process. Aggregate producers who pair the right shredder parts to the right stage will be the most efficient and, consequently, the most profitable.


The crushing stages


Many aggregate producers are familiar with the choice of crushing equipment and know it is possible to choose the right equipment solely on spec sheets and Gradation calculations. But, it is crucial to weigh theoretical conclusions against the actual experience of the material, as well as the maintenance, economic and operational features of different options.


The process of reduction usually takes place in stages. There are single-crusher models, but the most common systems require at minimum two or three crushing stages.

Primary crushing. The duty of the primary crusher is, above all making it possible to move material along a conveyor belt. In most aggregate crushing facilities the primary crushing process is performed in a jaw crusher, although a gyratory primary crusher may be used. If material is easily crushed and isn't excessively abrasive an impact crusher could be the best option.


The most important characteristics of a primary crusher are the capacity and the ability to accept raw material without causing blockages. Bigger primary crushers can be more costly to buy than smaller ones. This is the reason why the initial investment costs for primary crushers are assessed against the expense of blasting raw materials into a smaller size.



 


In most cases trucks move raw materials to a fixed primary. It is important to be aware of the costs associated with fuel, tires and maintenance and the investment return.

When the quarry's face is crushed, pit-portable primary crushers is an efficient and cost-effective choice. In modern plants it is common to have a mobile primary crusher to be able to follow the motion of the quarry face from which raw material is removed.


Intermediate (secondary crushing). Intermediate crushing can be used to produce coarser fractions and prepare the material for final crushing. When the intermediate crusher will be employed for making railway ballast it is essential to ensure the product's quality.


In other situations, there are normally no quality requirements, although the product must be suitable for fine crushing. The objective is typically to achieve the lowest cost and the highest reduction.


Fine crushing (tertiary). This stage is what determines the quantity and quality of of fine products. Quality requirements can be stringent for the final product, particularly in the aggregate industry.


In most cases, the fine crushing and cubicization processes are combined into one crushing stage. The selection of the appropriate crusher for tertiary crushing calls for an understanding of the practical as well as the theoretical knowledge. This is why manufacturers should ensure that they contact an experienced applications specialist to ensure that the machine is designed and constructed correctly.


Types of crushers


Jaw crushers


Jaw crushers are an example of a crusher that is compressed. The material can be reduced by compressing it between two pieces steel. The setting or distance between two pieces of steel is what controls the size of the discharge. The setting is more precise, which results in less output and lower throughput capacity.

Jaw crushers are a compression crusher , and create the most coarse material. This is because they crush rock with the natural lines of weakness. Jaw crushers can be used as primary crushers in order to prepare the rock for further processing.


Cone and gyratory crushers


They also crush steel between two steel pieces. The position between the two pieces determines the output.


The chamber is circular in shape however the steel moving part is not intended to rotate. Instead the wedge is driven around to create compression on one side of the chamber, and a discharge opening on the opposite side. Cone crushers can be used in secondary and tertiary crushing, but they should have an extremely low percentage of fines.

Impact crushers


An impact crusher uses speed and mass to break down feed materials. The feed material first gets reduced as it enters mill liners foundry that is rotated by the hammers or blow bars of the rotor. Secondary breakage occurs when the material is then accelerated to stationary aprons as well as breakers plates.


When shape is important the impact crusher is often employed. Impact crushers crush rock along natural cleavage lines. This results in better quality product and shape.

Final thoughts


When selecting the crusher to best meet your requirements It is important to know your needs for each step.


During the primary stage, look to get materials that are of a size that conveyors and other equipment can manage.


Some operations require further crushing at the secondary or tertiary stages. These stages can be used to more effectively control and size the output.

Understanding how to best match the crusher with the appropriate crushing stage will ensure crushing efficiency throughout your process and will ultimately improve your overall financial success.