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09
2024
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08
Common Types of Crushers, Their Applications, and Influencing Factors in the Crushing Process
In the field of ore and mineral processing, commonly used crushers include jaw crushers, impact crushers, cone crushers, roll crushers, hammer crushers, double roll crushers, rod mills, and gyratory crushers. Below is a detailed introduction to these common crushers:
I. Types of Crushers
1. Jaw Crusher
Features:
Simple structure, easy manufacturing, reliable operation.
High crushing ratio, uniform product size.
Easy maintenance, low operating cost.
Parameters:
Feed opening size: 150×250 mm to 1500×2100 mm
Maximum feed size: 125 mm to 1500 mm
Discharge opening adjustment range: 10 mm to 300 mm
Production capacity: 1 t/h to 1000 t/h
Motor power: 5.5 kW to 220 kW
Applications:
Suitable for coarse or medium crushing operations of various ores and rocks with a compressive strength not exceeding 320 MPa.
Common ores: iron ore, copper ore, gold ore, lead-zinc ore, limestone, granite, basalt.
2. Impact Crusher
Features:
High crushing ratio, cubic product shape.
Simple structure, easy manufacturing and maintenance.
Strong impact and wear resistance, long service life.
Parameters:
Feed opening size: 300 mm to 700 mm
Maximum feed size: 250 mm to 700 mm
Discharge opening adjustment range: 20 mm to 200 mm
Production capacity: 30 t/h to 800 t/h
Motor power: 37 kW to 630 kW
Applications:
Suitable for processing various ores and rocks with a compressive strength not exceeding 350 MPa.
Common ores: limestone, granite, basalt, river pebbles, construction waste.
3. Cone Crusher
Features:
Strong crushing force, high efficiency, large output.
Uniform product size, good grain shape.
Simple structure, convenient adjustment, safe operation, economical use.
Parameters:
Feed opening size: 50 mm to 400 mm
Maximum feed size: 35 mm to 300 mm
Discharge opening adjustment range: 3 mm to 60 mm
Production capacity: 12 t/h to 1000 t/h
Motor power: 30 kW to 750 kW
Applications:
Suitable for medium and fine crushing operations of various hardness ores and rocks.
Common ores: iron ore, copper ore, gold ore, granite, basalt, limestone.
4. Roll Crusher
Features:
Small crushing ratio, suitable for medium and fine crushing.
Smooth operation, low noise, less dust.
Simple structure, easy maintenance.
Parameters:
Feed opening size: 25 mm to 500 mm
Maximum feed size: 20 mm to 400 mm
Discharge opening adjustment range: 2 mm to 50 mm
Production capacity: 5 t/h to 300 t/h
Motor power: 5.5 kW to 200 kW
Applications:
Suitable for medium and fine crushing operations in mining, cement, chemical, building materials industries.
Common ores: coal, gangue, coke, limestone, feldspar, dolomite.
5. Hammer Crusher
Features:
Large crushing ratio, uniform product size.
Simple structure, easy manufacturing, convenient maintenance.
Low energy consumption, low operating cost.
Parameters:
Feed opening size: 100 mm to 800 mm
Maximum feed size: 60 mm to 400 mm
Discharge opening adjustment range: 0 mm to 75 mm
Production capacity: 5 t/h to 1500 t/h
Motor power: 11 kW to 800 kW
Applications:
Suitable for medium and fine crushing of various medium-hard and brittle materials such as limestone, coal, gypsum, shale, bricks, tiles.
Common ores: limestone, coal, gypsum, shale.
6. Double Roll Crusher
Features:
Small crushing ratio, suitable for medium and fine crushing.
Uniform product size, less over-crushing.
Low noise and dust: smooth operation, environmentally friendly.
Parameters:
Feed size: ≤30 mm
Discharge size: 2 mm to 8 mm
Production capacity: 10 t/h to 100 t/h
Power: 5.5 kW to 45 kW
Applications:
Suitable for medium and fine crushing operations in mining, chemical, cement, building materials industries.
Common ores: coal, gangue, coke, limestone.
7. Rod Mill
Features:
Good grinding effect: uses steel rods as grinding media, with strong selectivity during grinding.
Less over-crushing: suitable for fine crushing and coarse grinding of ores, reducing over-crushing.
High production capacity: compared to ball mills, has higher production capacity.
Parameters:
Feed size: ≤50 mm
Discharge size: 0.5 mm to 2 mm
Production capacity: 0.62 t/h to 180 t/h
Power: 30 kW to 1800 kW
Applications:
Widely used in fine crushing and coarse grinding of metal and non-metal ores, such as ore, chemical, building materials, etc.
Common ores: iron ore, gold ore, copper ore, limestone.
8. Gyratory Crusher
Features:
High production capacity: suitable for large-scale production lines, with extremely high processing capacity.
Continuous operation: can work continuously for a long time, suitable for large-scale mining operations.
Large crushing ratio: capable of handling large blocks of material.
Parameters:
Feed size: ≤1500 mm
Discharge size: ≤250 mm
Production capacity: 200 t/h to 8895 t/h
Power: 200 kW to 1500 kW
Applications:
Suitable for large-scale mining and ore crushing operations, such as metallurgy, building materials, chemical industries.
Common ores: copper ore, iron ore, gold ore, limestone.
II. Factors Affecting the Crushing Process
The crushing process is influenced by several factors, including:
1. Ore Properties
Hardness: The hardness of the ore directly affects the choice of crusher and the crushing efficiency. Harder ores require crushers with higher strength to process.
Moisture: High moisture content can cause ores to stick to the crusher walls, leading to blockages and reduced crushing efficiency.
Particle Size: The initial particle size of the ore determines the required crushing stages and the type of crusher to be used.
2. Performance of Crushing Equipment
Crusher Specifications: Different specifications of crushers are suitable for different production capacities and particle size requirements. Choosing the right crusher specifications can improve crushing efficiency and product quality.
Crusher Nip Angle: The nip angle is the angle between the moving jaw and the fixed jaw. A reasonable nip angle can enhance the crushing ability and production efficiency of the crusher.
Typical range: 18° to 22°
Optimal range: Around 20° is considered ideal, balancing crushing effect with reduced material slippage.
Example: A certain jaw crusher model has a design nip angle of 21°, which provides high efficiency and low wear when crushing hard granite.
Liner Material: The material of the crusher liner directly affects the wear resistance and service life of the equipment. High wear-resistant materials can extend the crusher's service life and reduce maintenance costs. Common liner materials include:
High Manganese Steel:
Composition: 12%-14% manganese, 0.9%-1.4% carbon.
Characteristics: High wear resistance, suitable for crushing hard ores.
Applications: Widely used in the moving and fixed jaw plates of jaw crushers and the liners of cone crushers.
Medium Carbon Alloy Steel:
Composition: 0.3%-0.8% carbon, alloy elements such as vanadium, molybdenum, nickel.
Characteristics: Good overall performance, balanced wear resistance and toughness.
Applications: Suitable for crushers handling medium-hard ores.
High Chromium Cast Iron:
Composition: 12%-30% chromium, 2%-3% carbon.
Characteristics: Extremely high wear resistance, but low toughness; suitable for fine crushing machine liners.
Applications: Used in fine crushing stages, such as VSI crushers and equipment in high-wear environments.
Ceramic Matrix Composites:
Composition: Metal matrix with embedded ceramic particles.
Characteristics: High wear resistance and corrosion resistance; suitable for extreme wear environments.
Applications: Used in crushers' liners in extremely high wear and corrosive environments.
3. Operational Conditions
Feed Rate: Proper feed rate ensures the efficient operation of the crusher. Both excessive and insufficient feed rates can affect the crushing effect and the stability of the equipment.
Operating Pressure: The operating pressure should be controlled within the allowable range of the equipment. Both high and low pressure can impact the crushing effect and equipment safety.
Maintenance: Regular maintenance can ensure the normal operation of the crusher, extend the equipment's service life, and reduce the failure rate.
Each type of crusher has its unique advantages and applicable range. Users should choose the appropriate crusher type based on specific crushing needs. In the process of ore and mineral processing, a reasonable selection and configuration of crushers can effectively improve production efficiency, reduce energy consumption, optimize production costs, and enhance product quality.
If you have any questions or needs, please feel free to contact us by phone or online.
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