It is essential to select the correct crusher for each operation. Knowing the various stages of crushing and the types of crushers that are best suited to each stage will make it easier to choose the appropriate equipment. Each type of crusher serves a different purpose and is designed to achieve an exact end-product.

Like the previous stage, each crushing stage is expected to generate a specific output in the subsequent phase. Aggregate producers that match the proper shredder parts stage with the correct stage will be the most efficient and profitable.

Crushing stages

Aggregate producers are familiar with choosing the right crushing equipment. They are aware that it is possible to pick the correct equipment piece based upon specifications and gradation calculations. However, it is important to evaluate the theoretical implications against the practical experience with the material and the economic, maintenance and operational features of different options.

Material reduction generally takes place in stages. Although there are single crusher choices, the most popular systems include at minimum two or more crushing stage.

Primary crushing. Primary crushing is the process of making it possible to transport material using a conveyor belt. In the majority of aggregate crushing plants, primary crushing is carried out by a jaw crusher although a gyratory primary crusher can be used. A crusher with an impact is an option if the material is easy to crush and not too abrasive.

The most significant attributes are its capacity and capability to handle raw material without causing obstructions. A big primary crusher will be more costly to purchase than a smaller machine. This is why costs of investment for primary crushers must be evaluated against the costs of blasting raw material into smaller sizes.

Trucks transport materials from one location to another. The expenses of maintenance, fuel, tires and the return on investment must also be considered.

A pit-portable primary crusher can be a cost-effective solution when the manufacturer is crushing on the quarry's surface. In modern facilities it is usually advantageous to employ a moveable primary crusher so it can be able to follow the motion of the face where raw material is extracted.

Intermediate (secondary) crushing. The purpose of the intermediate crushing process is to make various coarser fractions or to prepare material for crushing in the final stage. The quality of the product is crucial when the intermediate crusher is going to be used for railway ballast.

In other cases, there are normally no quality standards, however the product should be suitable for fine crushing. The aim is to achieve the lowest cost and the highest reduction.

Fine (tertiary) crushing. At this stage the quality and quantity of fine-quality products are determined. The quality requirements may be strict for final products, specifically within the aggregate industry.

In most cases the function of fine crushing and cubicization are combined in a single crushing stage. Experience in the field as well as the theoretical understanding are essential when selecting a crusher for secondary crushing. This is why manufacturers should ensure that they contact an experienced applications specialist to make sure a device is well-engineered.

Types

Jaw crushers

A jaw crusher is a type of compression crusher. It can reduce the size of material by pressing it between two pieces of steel. The setting or the distance between two pieces of steel determines the size of the discharge. The setting is more precise, that results in an output that is smaller and a lower capacity for throughput.

In the context of a compression crusher jaw crushers typically produce the most coarse materials because they break rock through the natural inherent lines of weakness. Jaw crushers can be used as a primary crusher in order to prepare the rock for further processing.

Cone Crushers and Gyratory Crushers

These are also compression-type machines that crush materials between a stationary and a stationary steel piece. The output is controlled by the setting between the two pieces.

The chamber is circular but the steel moving piece is not designed to rotate. Instead the wedge is employed to reduce one side of the chamber and discharge openings are made on the other. Cone crushers are used in secondary and tertiary functions as an alternative to impact crushers when shape is an important requirement however, the amount of fines produced must be reduced.

Impact crushers

Impact crushers use velocity and mass to reduce the amount of feed material. The material feed is reduced when it enters the crusher liners with the rotating blow bars or hammers in the rotor. Second, the break occurs after the material is accelerated into stationary aprons as well as breakers plates.

When shape is important, impact crushers are often used. The crushing force of an impact crusher splits a rock along natural cleavage lines, giving rise to better quality products in regards to shape.

Final thoughts

When choosing the crusher that will best meet your requirements it is crucial to comprehend the requirements for each step.

In the first phase, ensure that you purchase a material large enough to support your conveyors as well as other equipment used for processing.

Some operations require further crushing at the secondary or tertiary stages. These stages allow for more control over the amount and form of the final product.

You can maximize the effectiveness of your crusher and maximize your profits by matching the appropriate crusher to the appropriate stage.