Most machinery starts out as a crude device that has undergone significant changes before it becomes the machine that we use today. The rock crusher was first introduced in 1830, and it consisted of a drop hammer. Since then, the rock crusher has become a widely used piece of equipment on many construction sites, and it has taken many forms. Here is a list of different types of rock crushers and what projects they would be used on.
A jaw crusher uses a constantly moving metal piece that crushes the stones on a situated metal piece in small movements. It is called a jaw crusher because it works the same was a human jaw does-food goes into your mouth and your bottom jaw pushes the food up against your fixed top jaw. The jaw crusher is usually made of cast steel because it is such a heavy duty machine. There are three types of jaw crushers: Blake crusher, Dodge crusher, and the Universal crusher. The type of jaw varies, which makes the different jaw crushers preferred for certain projects. For example, the Dodge crusher is used for laboratory purposes and not as heavy duty machinery because it can get clogged too easily, making it useless for large-scale projects.
Similar to a jaw crusher, the gyratory crusher pulverizers the stones by placing them between two manganese steel plates and going straight down. It does not rotate, rather it is powered by electricity. Gyratory crushers are used in mine or ore processing plants and they can be used for primary or secondary crushing. It crushes rocks by rotating the vertical shaft and crushing the rocks in a circular motion where they fall out the narrow bottom when they are small enough.
The cone crusher can be divided into four subtypes: compound crusher, symons cone crusher, single cylinder hydraulic cone crusher, and the multi-cylinder hydraulic cone crusher. The basic structure of the cone crusher is similar to a gyratory crusher but much wider. It spins around and crushes the stone against the side of the machine, where it falls down into a lower chamber and is crushed again until it falls out the bottom. The cone crusher is used on construction sites because it produces great results, it relatively cheap and it has a built-in function that allows it to correct itself when it becomes overloaded with rocks.
These crushers dont use pressure to crush rocks, rather they use a rotating motor that uses impact to crush the rocks against the sides of the large metal cage. The cage can be adjusted to the size of the rock that is needed and once the rock is small enough, it falls out the bottom of the cage. Impact crushers were originally used for softer stone like limestone and gypsum but due to improved design, it can handle much tougher stones. There are two kinds of impact crushers: the horizontal shaft impactor and the vertical shaft impactor.
Rock crushers are used in construction projects all around the world have been used for decades. They are an important piece of machinery that comes in a variety of different types. This list includes a description of the different types of rock crushers so you can make an informed decision when choosing one for your next project.
Were proud to sell and service a range of industry-leading rock crushers. From jaw crushers to cone crushers and from stationary plants to mobile crushers, we offer a selection of models and parts that can suit any rock crushing need so we have a wide-ranging familiarity with the industrys leading brands.
Pegson was well-known for dependable lines of jaw crushers and cone crushers. The company was headquartered in the UK, but American distributors have helped to facilitate the provision of Pegson machines on this side of the Atlantic for decades.
Cedarapids is also owned by Terex, but this brand is still on the market. Cedarapids crushers are designed specifically to be modular machines, allowing them to be flexible in application and making setup efficient.
Home to the number one portable crusher in the world, Eagle Crusher supports the industry with it's extensive catalog of equipment options. Eagle produces an extensive catalog of heavy-duty impact crushers, portable crushing and screening plants, jaw crushers, and conveyors.
They offer mining jaw crushers, cone crushers, impact crushers, roll crushers and primary gyratory crushers for mining, quarrying and aggregate production, and boast expertise in a broad range of applications from greenfield mining projects to site expansions.
Allis Chalmers is another long-respected company that, today, has been dissolved into several different entities (none of which continue to provide rock crushers). However, as with Pegson rock crushers, there are still many Allis Chalmers rock crushers and parts available for resale.
Its widely held that the Symons brothers designed the first spring cone crusher in the late 1940s. Today, Symons isnt a brand as much as it is a type of crusher; the word is still used to denote machines that use this cone crusher technique. However, since it was the original brand, it merits an inclusion on this list.
Extec is another rock crushing brand thats still widely available for resale. Extec was based in the UK with a network of global distributors and was known for its leading design and manufacturing of mobile crushing machines.
If youd like more insight into any of these brands, get in touch with us. At Mellott Company, we have experience in servicing a broad range of rock crusher brands, including all of those listed here. Were experts at navigating all of the different components of rock crusher selection, setup, and maintenance.
Reducing the size of material for transport, building, and recycling is critical. Crushers were invented to make the task of breaking down rocks and other materials much easier. Although crusher technology is not particularly sophisticated, selecting the right crusher can take some time. In this article we discuss the different types of crushers and what you need to consider before you buy.
The first viable crusher (known as a mechanical rock breaker) was invented by Eli Whitney Blake in 1858. Another inventor, Philetus W. Gates, patented the first gyratory crusher in 1881. There were crushers patented before Whitneys, but they never made it into production. Since the late 1800s, the size of crushers has greatly increased, but the engineering principles that make them work have remained the same. Both jaw crushers and gyratory crushers are still used today.
The selection of any major piece of equipment entails having a detailed understanding of your job requirements. In choosing the right crusher you must know these key aspects of the material youll be handling:
Dimensions. What is the thickness, length, and width of the material you will feed into the crusher. A large crusher can process rocks up to three feet in diameter. A hydraulic hammer is used to break up larger pieces before they are fed into the crusher.
Obviously, dimension is in essence just measuring the maximum size of the material that will be fed into the crusher. The granulometric requirement is based on how the final product will be used. However, abrasiveness and hardness factor are known through testing and calculation.
The Rock Abrasiveness Index (RAI), introduced in 2002, is often used to categorize abrasiveness. This informs a rocks resistance to crushing as well as its wear and tear on the crusher. Highly abrasive rocks include granite, quartzite, and basalt.
As discussed in our article Get to Know the Common Types of Mining Equipment there are three classifications of crushers: primary, secondary, and tertiary. Crushers are further categorized by how they crush the material.
To understand the difference between the crushing phases, typical examples include reducing topsize from 900 to 300 mm for primary, 300 to 100 mm for secondary, and under 5mm for fine crushing, such as manufactured sand.
A jaw crusher is the most commonly used primary crusher. It uses simple technology to break down large blocks into smaller pieces. Their simplicity requires little engineering expertise to operate. A jaw crusher is reliable and needs less maintenance than other types of crushers.
A jaw crusher has one fixed and one moving surface in a V-shaped configuration. The moving jaw is mounted on an eccentric shaft. The reciprocal motion of this jaw presses the material against the fixed jaw. Rotational movement is achieved via a motor and a belt. The space between the jaws narrows as the material moves downward. Once crushed to the desired size, the material falls through the bottom of the jaw crusher.
An impact crusher (also called a hammer crusher) is quite versatile. It can be used as a primary, secondary, or tertiary crusher. Impact plates and beaters or hammers are used to break down the material. The material is fed through the upper part of the crusher then hit by hammers. Next, the pieces are thrown toward the plates. This further breaks the material. The pieces bounce back to the hammers. The material is thrown back and forth between the plates and hammers until it is reduced to the target size.
Impact crushers can handle an array of materials, including clay, dirt, and metal that may be mixed in with the feed material. An impact crusher can have a horizontal shaft or a vertical axis. This type of crusher may not be as effective for producing smaller pieces. The force needed to break down the material depends, in part, on the energy generated by the broken pieces. The smaller the piece the less energy its impact against the hammer produces. Impact crushers have a high production capacity, low energy consumption, and produce a uniform grain size. However, their operating costs are often higher than jaw crushers.
A cone (or conical) crusher breaks down material with the use of an eccentric rotating head and a bowl. It is often used as a secondary or tertiary crusher. It is best for crushing material 200 mm and less. Advantages of a cone crusher include high productivity and low operating costs. However, a cone crusher does not generate evenly sized pieces that are often required.
A gyratory crusher has a mantle that rotates within a concave bowl. Gyratory crushers and cone crushers are quite similar. A gyratory crusher has a higher angle at the apex of the cone. Its name refers to the constant back and forth motion that compresses the material against the chamber walls. They are often used as primary crushers.
There are mobile crushers that can maneuver around a job site. On some projects it is more cost-effective to not have to transport material to a centralized crusher for processing. Or a site is just too small for a large piece of equipment and requires a crusher with a smaller footprint.
The eccentric throw range is related to how much the crushers mantle veers away from its axis. This determines the rate the material will fall through the chamber. Crushers with a high eccentric thrown will allow particles to fall farther in a single revolution. This results in a coarser product.
Crusher technology keeps evolving in terms of automation and safety. Some of todays crushers are equipped with systems that will adjust the CSS (Closed Side Setting) without your having to shut the machine down. The crusher can ensure the bearings are not exceeding normal operating temperature. There are also safety features that will automatically shut down the machine when it encounters out-of-spec material, such as rubber or steel. This protects the shaft or bearing against damage. If youre working on a tight budget, we recommend machine power and brand name over bells and whistles. Larger organizations can usually justify high-cost automation features.
Eagle Crusher claims they sell the number one portable crusher worldwide. Their UltraMax Impactor line offers Horizontal Shaft Impactors (HSIs) that handle primary and secondary crushing in one unit. These units come in stationary, skid-mounted, or portable configurations. Eagle Crusher offers financing and 24/7 service. Made in the USA.
Powerscreen began as Ulster Plant in 1966 in Ireland. Its changed hands through the years but became Powerscreen in 2009. Its parent company is Terex. They manufacturer in several countries, including the US (in Louisville, Kentucky). They offer a wide variety of jaw, cone, and impact crushers. Their Metrotrak model is a compact, mobile unit offering an output of about 200 tph. It weighs around 60 thousand pounds. The Metrotrak is only 12.5 feet wide and a just under 41 feet long. Its low height of 10 foot, 6 inches gives you the ability to handle crushing in tight spaces.
They sell many types of crushers including several stationary cone crushers. Their CS420 is a high-production, compact stationary cone crusher. Sandvik offers their proprietary Automatic Setting Regulation control system (ASRi) This real-time performance management system will automatically adjust based on feed conditions. They also offer crushers that offer safety features and a system to streamline settings adjustment.
You can buy new or used directly from the manufacturer or a local equipment dealer. Financing options may be available. We recommend putting together a requirements document and letting the dealer tell you which crusher (or crushers) will meet your needs. Then you can shop it around for estimates.
Leasing is a great idea to try before you buy. However, depending on the size of your organization, it may make sense to take advantage of contract services that a company like Metso:Outotec offers. Compare it to the total cost of ownership. Its not just the cost of the machine its maintenance and repairs, hiring operators, and storing the equipment.
Buying used is only risky if you dont work with a reputable dealer. Youll want an experienced and knowledgeable operator to perform the inspection. Warranty and service agreements must be in writing. Be sure to understand what the resale value might be. Some brands and models hold their value more than others.
When youre inspecting a used crusher, take a close look at the wear parts. These are parts of the machine that are expected to be replaced periodically. For example, manganese liners protect the mantle and concaves of a cone crusher. The fixed jaw of a jaw crusher is subject to the most wear and tear. (In fact, Hardox offers cheek plates made of a material that they claim can greatly increase the life of your jaw crusher.) Take an inventory of worn parts and get quotes for replacements. There are companies that specialize in spare crusher parts such as Norther Crusher Spares.
Selecting the right crusher is highly dependent on your job requirements. Crushing rock and other hard materials is not a complicated process but selecting the wrong machine for the job can be dangerous. Low production or results of the wrong size grain can have a negative impact on your bottom line. Work with your local equipment dealer to select a machine that will meet your documented requirements. Explore safety and other automation features that will protect your workers and reduce production costs.
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