This brings us to the rather significant fact that, while all of the interesting and rather remarkable development we have outlined was going on, very little, if anything, was being done to develop special crushers for secondary and fine-reduction work, other than the work on crushing rolls just described.
Crushers may be divided into three general classes, with respect to the manner in which they do their work: Pressure Crushers: This category embraces the several types of gyratory crushers and jaw crushers, as well as the double crushing rolls, with either smooth or corrugated shells. Here are several, but not all, types of crushers: Double Toggle Jaw Crusher. Single Toggle Jaw Crusher. Cone Crusher. Head Rock Impact Breaker.
Three-Roll Crusher. Smooth Roll Crusher. Two-Tube Vibratory Crusher. Perforated Stepped Lump Loosener. Single Roll Lump Breaker. The other type consists of a centrifugal crusher with vertical shaft, generally known as VSI. Impactor operation is based on the principle of rapid transfer of impact energy to the rock material. Impactors produce cubic products, and they can offer high reduction ratios as long as the feed material is not too fine. This means that in certain cases it is possible to use a single impact crusher to carry out a task normally done in several crushing stages using compressing crushers i.
Impactors are mostly used for nonabrasive materials. Conventional horizontal-shaft impact crushers are available in various sizes and models, from high-capacity primary crushers for large limestone quarries to specially designed machines for the crushing of materials such as slag. There are two main categories of VSI crushers — machines with impact wear parts around the body and machines that use a layer of accumulated material. The first type is in many respects similar to the conventional impactor with horizontal shaft and rotor.
The second type became quite popular in the past decade and is known as the Barmac crusher. The difference between a conventional impactor and a VSI of the Barmac type is that the latter offers lower operating costs, but its reduction ratio is lower also.
In a Barmac VSI, the material undergoes an intense rock-on-rock crushing process. In the other crushers, most of the reduction is done by the impact of stone against metal. Customers operating old, rebuilt, or expanded plants often have problems with the shape of the product. In these cases, the addition of a Barmac VSI in the final crushing stage offers a solution to product shape problems. The same applies to many mobile crushing units.
As the number of crushing stages is normally small with this type of plant, it is almost impossible to obtain a good product shape unless the rock is relatively soft and thus more suited for the production of cubic product. A centrifugal crusher in the final stage can help to solve the problem. When choosing wear parts for your crusher, think long-term. Our parts help keep your crusher working at peak performance because they Minimize downtime, increase capacity, lower your cost per ton, or meet specific size-reduction requirements.
Get the maximum potential out of your size reduction process to achieve improved crushing performance and lower cost per ton.
By using our unique simulation software, our Chamber Optimization experts can design an optimized crushing chamber that matches the exact conditions under which you operate.
Learn more about our Chamber Optimization Program. Home Products and Services Plants and capital equipment Crushers - All crusher types for your reduction needs. Crushers For any size reduction needs. Crushers are machines used to reduce the size of rocks, stones and ore. They are often utilized in aggregates production, construction material recycling and in mining operations.
Metso Outotec offering covers different gyratory crushers, jaw crushers, cone crushers and impact crushers — optimized for any size reduction need. Crusher families. Crusher selection. Different types of crushers are optimal for distinct crushing needs. Jaw crushers Jaw crushers are mainly used as primary crushers. Gyratory crushers Gyratory crushers are frequently used in the primary crushing stage and a little less often in in the secondary stage.
Cone crushers Cone crushers resemble gyratory crushers from technological standpoint, but unlike gyratory crushers, cone crushers are popular in secondary, tertiary, and quaternary crushing stages. Impact crushers Impact crushers are versatile crushing machines that can be used in any stage of the crushing process. How to select an optimal crusher? Primary crushing. Primary crushing with different types of crusher.
Primary crushing with jaw crushers In terms of the size of the feed opening, the client gets a better return on investment when the primary crusher is a jaw crusher.
Primary crushing with gyratory crushers The primary gyratory crusher offers high capacity thanks to its generously dimensioned circular discharge opening which provides a much larger area than that of the jaw crusher and the continuous operation principle while the reciprocating motion of the jaw crusher produces a batch crushing action. Primary crushing with impact crushers The primary impact crusher offers high capacity and is designed to accept large feed sizes.
Intermediate crushing. Intermediate crushing with different types of crushers. Fine crushing. Fine crushing with different types of crushers. Fine crushing with cone crushers Due to their design, cone crushers are generally a more expensive investment than impactors are. This means that cone head must be covered by rock. Stable and continuous feed.
Maximum feed size. Reduction ratio must be limited to 3 Recommended max feed size is 50 mm. Correct feed distribution. Feed distribution should be non segregated and evenly distributed around crushing cavity. Setting closer to required product Correct choke point. This means the right selection of cavities for feed in question. Crusher itself.
New generation cones will produce considerably better shape than so called old generation. A wider setting also provides greater throughput. Single Roll Crushers feature a low-speed crushing roll that crushes material against a curved crushing plate. They require lower headroom than other primary crushers and produce minimal fines. However, Single Roll Crushers provide limited product sizing and are limited in throughput capacity.
Double Roll Crushers feature two rotating roll shafts that crush material between the teeth and roll bodies. These types of Roll Crushers produce a cubical product with minimal fines generation, and can handle higher capacities. In the correct application, Triple and Quad Roll Crushers are capable of performing both primary and secondary stages of material reduction in one machine.
The top stage of a Triple Roll Crusher has a ratio of reduction, whereas the bottom stage has a In a triple-roll configuration, the primary stage of crushing occurs in the top stage of the crusher and features a single roll configuration that performs the initial crushing.
A double-roll arrangement on the bottom stage of the machine accepts the sized material from the top stage and sizes it further. It is ideal for handling larger feed sizes due to the design and larger feed opening.
In a quad-roll configuration, both the top and bottom stages have a reduction ratio. The primary crushing stage at the top of the machine and the secondary stage at the bottom of the machine both consist of a double-roll arrangement.
Due to the feed opening and design of the top stage, these types of Roll Crushers are best for handling medium sized feed material. Like the other Roll Crushers listed, Triple and Quad Roll Crushers produce a cubical product with minimal fines generation. Cone Crushers are compression-type crushers that are typically found in secondary crushing stages but can be used as the primary crusher in certain applications. They handle medium hard to very hard, abrasive materials that can be dry or wet but not sticky.
Cone Crushers are typically found in quarried materials and sand and gravel applications. Material that enters a Cone Crusher is compressed between a wobbling mantle and the concaves inside the crushing chamber. The gradation is controlled by adjusting the spacing between the mantle and the concave at their closest point. This is accomplished by raising and lowering the top or bowl of the crusher.
A finer setting will create a finer product but at a lower throughput. Speed can also help to determine the final output gradation. Faster speed, for finer feed, is used to produce a finer output. Feeder-Breakers , which combine both feeding and crushing into one machine, are used for the primary crushing of friable materials that can be slightly abrasive, dry or wet, but not sticky.
They are typically used in heavy mining applications to provide the primary crushing and to make a beltable product to be conveyed for further downstream processing. These high capacity machines feature a chain and flight drag conveyor that meters material toward a horizontal pick. Run-of-mine material is conveyed toward the rotating pick roll, which crushes the material against the flights and conveyor deck. Since Feeder-Breakers size in one dimension only, secondary and even tertiary crushing stages may be necessary to achieve the desired product size.
They can be fed by a shovel, truck, loader or dozer and can be made portable for underground operations. Some crushers require pre-screening, and some accept all-in feed. Some crushers produce more fines than others. The material and its characteristics, e.
Knowing the material characteristics as well as the advantages and limitations of the different crusher types will help to determine the best primary crusher for a given application. We can ship you parts, send field service technicians to your site and answer any questions you have. Whatever you need, we are here for you. March 25, There are several different types of primary crushers.
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