Do You Have A Project Related To Materials Crushing And Classification?
General information
Crushers are equipment for providing a mechanical impact on solid materials in order to crush them. There is another name for crushers which is stone crushers. Our company produces several types of crushers. Together with our partners, we purchase some other types of crushers that we don’t produce yet. As raw materials, our equipment uses both hard and soft rocks. Different rocks have different characteristics, so we use several types of stone crushing units in order to crush them. In some cases, one type of crusher is enough for our equipment, however, in other cases, we have to equip more complex crushing and screening lines.
The choice of the required crusher (s) should be made according to the following parameters:
- the size of the particles that we have to obtain;
- the hardness of the original material;
- unit performance;
- repairability.
The purpose of crushers is to break the material and split it into smaller pieces. Depending on the size of the output material, the crushers are divided into units of fine, medium, and coarse crushers.
| Crusher type | Size of the original raw material (input particle size), mm | Side of the processed raw material (output particle size), mm |
|---|---|---|
| Coarse crusher | 600—1000 | 100–300 |
| Medium crusher | 100–300 | 25–100 |
| Fine crusher | 50–100 | 1-25 |
Classification of crushers according to their operating principle
There are different designs of crushers that perform the following types of crushing:
- crushing,
- tearing,
- cutting or loosening,
- shock impact (impact bars, hammers, impact plates),
- shock impact (free-fall impact, ”rock against rock” impact).
Crusher classification according to the design
According to their design, crushers are divided into the following groups:
- Jaw crusher
- Cone crusher
- Hammer crusher
- Roller crusher
- Disc (impeller/chopping) crusher
We should also mention mills, among which the most popular types are:
- Ball mill
- Vibration mill
According to the installation method, crushers are divided into the following types:
- stationary crushers
- portable crushers on wheel landing gear or tacked chassis
Peculiarities of operation according to the type
Usually, a stationary crusher requires approved design documentation, construction works of different complexity (preparation of foundations, etc.), and the creation of an appropriate infrastructure. It usually takes 2-3 months in order to carry out the construction work. The installation of equipment (crushers) usually takes 2-3 months.
The portable crusher is self-propelled equipment that can be relocated within the quarry but requires specially organized transportation from place to place on public roads.
Advantages of the portable crusher:
- usually, you don’t need the approved project in order to start operation,
- as a rule, you don’t need a foundation to start operation (no construction works (or minor) are needed),
- activation into operating position takes minimal time – about 4-16 hours,
- portable crusher provides free movement throughout the quarry to the place of excavation, which excludes the primary transportation of raw materials.
There are very light stationary crushers, which allow organizing their installation without a special foundation, which allows saving time for dismantling and installation of a unit at a new place.
Use of crushers for additional crushing of rock screenings (waste from rock crushing)
As raw materials, our equipment very often uses rock screenings. Rock screenings are waste from rock crushing. The thing is that the fraction of 0-10 mm (or 0-5 mm) size is used in just a few places. As a result, screenings are accumulated in dumps in a large quantity. This fraction is a perfect raw material for our hyper presses (as well as other equipment), however, it requires additional grinding, usually to 0-3 mm fraction.
Several types of crushers can be successfully used in order to crush raw materials to a 0-2 (0-3) mm fraction:
- roller crusher;
- hammer crusher.
A roller crusher is especially preferable for this purpose because it requires less maintenance. Rollers made of high-quality steel allow the roller crusher to operate without maintenance for a year or more.
A hammer crusher is a very simple and cheap unit, however, it requires relatively frequent replacement of hammers (steel plates). For example, even when working with limestone, the hammer set has to be replaced every 2-3 weeks.
Both crushers are sensitive to excessive moisture in the raw material.
Use of crushers for work straight in a quarry
In order to obtain particular fractions, the material should be crushed. To do this, several crushers are usually used. For example, for primary crushing, one type of crusher is used (for example, a jaw crusher). In order to receive medium-sized particles, a different type of crusher is required (for example, an impact crusher). If you need to get a finer fraction, you’ll need a third type of crushers (hammer, roller, etc.). Each crusher is designed for work with a particular particle size input, it often transfers the finished particles to a screen. In order to get powders (as a result of even greater material grinding), one should use mills. If the size of the rocks is too large even for the first stage of processing, special rock splitters are used.
Crushers are used to obtain a fine fraction of raw materials, which can be used for particular purposes or be further crushed with the help of mills.
During operation, raw materials of different sizes are transported by excavators, front-end loaders, and dump trucks. As a result, they enter the feeder. The feeder delivers the raw material into a preliminary classifier (screen) for the selection of particles that don’t have to be grind.
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Vibrating screen
A vibrating screen (a bolter) is a bolting unit that is used in different industries (mining, food, etc.). The “bolter” term is more commonly used in order to describe mining equipment.
Rotating drum
The rotating drum can evenly bolt even the most difficult materials by effectively using the feeding mechanism with automatic load control. The rotating screen has a large screening surface, which makes it possible to increase bolting performance.
Our Suppliers
We use components only from trusted suppliers!
- Proportional Hydraulics – Hengli, Bosh-Rexroth, Parker;
- Oil Pumps – PV series Yeoshe (Taiwan), Parker (Germany), Yuken (Japan);
- Electrical Components – Schneider;
- Power Supplies – Mean Well;
- Linear Motion Sensors – Senspro;
- Pressure Sensors – Wika;
- HID Interface – Weinview;
- Control System – based on Siemens controller;
- Electric Motors – Siemens;
- Piping – DIN 3865/DIN EN ISO 8434-4;
- Hydraulic Valves – standard ISO 4401.
