Selecting the appropriate crusher is essential for each process. Knowing the various phases of crushing and the different types of crushers that are best suited to each stage simplifies equipment selection. Each crusher type has a different purpose and is utilized to produce an exact end-product.

Similarly, a certain output is expected at the end of each crushing step for the next stage of the process. Aggregate producers that match the proper mill liners foundry and the right stage, will be the most efficient and thus and most profitable.

Crushing stages

Aggregate producers are well-versed in selecting crushing equipment. They know that it is possible to pick the correct equipment piece based upon specifications and calculative gradation. However, it is important to weigh theoretical conclusions against the practical experience with the material, as well as maintenance, financial, and operational features of different solutions.

In general, material reduction is handled in stages. Although there are single-crusher choices, the most popular systems contain at minimum two or more crushing stage.

Primary crushing. Primary crushing is the process used to make it possible to move material using the conveyor belt. The primary crushing process in the majority of aggregate crushing plants is done with the jaw crusher. But, a gyratory primary crush may also be used. If material is easily crushed and not excessively abrasive, an impact breaker may be the ideal option.

The most important characteristics of the primary characteristics of a shredder parts is its capacity and ability to take in raw materials without any blockages. Larger primary crushers are more costly to buy than smaller machines. This is why primary crusher investment costs are assessed against the expense of blasting raw materials to a smaller size.

Trucks transport materials from one place to the next. You should also consider the costs of maintenance, fuel, and tires, as well as the investment return.

Pit-portable primary crushers may be a cost-effective solution in cases where the producer is crushing at the quarry face. Modern plants it is common to have a mobile primary crusher to follow the movement of the quarry's face, where the raw material is being extracted.

Intermediate (secondary) crushing. The purpose of the intermediate crushing process is to create different coarser fragments or prepare the material for final crushing. If the intermediate crusher will be used to produce railway ballast, product quality is important.

Some cases do not have any conditions for quality, but the product has to be suited to fine crushing. The goal is usually to reduce costs to the minimum and the highest reduction.

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

In most cases the functions of fine crushing and cubing are combined in one crushing stage. The selection of crushing equipment for tertiary use is a matter of practical experience and theoretical know-how. In order to ensure the proper design of the system, the producers must consult an experienced application expert.

Types of crushers

Jaw crushers. A jaw crusher is a type of compression crusher. Material can be reduced by compressing it between two pieces of steel. The setting, or the distance between the two steel pieces, controls the discharge size. The setting is tighter which leads to an output that is smaller and lower throughput capacity. If you really want a full article about crusher liners, look at this website.

Jaw crushers are type of compression crusher that create the most coarse material. This is due to the fact that they crush the rock using the natural lines of weakness. Jaw crushers can be utilized as a primary crusher to make the rock ready for processing later.

Cone crushers and gyratory crushers. These are also compression-type machines that crush material between a moving and stationary piece made of steel. The setting between the two pieces determines the output.

The chamber is circular however the steel moving part is not designed to turn. Instead the wedge is driven around to cause compression on the one side and discharge opening on the other side. Cone crushers are used in secondary and tertiary roles as an alternative to impact crushers when shape is an important requirement however, the amount of fines produced must be minimized.

Impact crushers. Impact crushers use mass and velocity to reduce the amount of feed material. The first process is to decrease the material that feeds the crusher through the rotation of blow bars and hammers within the rotor. Secondary breakage occurs when the material is compressed to the stationary aprons or the breaker plates.

When shape is important in determining the shape of a rock, impact crushers are frequently used. The crushing process of an impact crusher cracks rocks along natural cleavage planes giving rise to higher quality products with regard to shape.

Final thoughts

It is crucial to fully know the requirements of each stage before deciding the right crusher for your business.

In the initial stage, try to bring the material to a size your conveyors and other equipment can handle.

Certain operations require additional crushing in the secondary or tertiary stage. These stages provide greater control over the size and form of the output.

Understanding how to best match the crusher with the appropriate crushing stage will ensure crushing efficiency throughout the entire operation and ultimately financial success.

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