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efficient stone impact crusher

4 types of stone crushers' maintenance and efficient improvement | fote machinery

4 types of stone crushers' maintenance and efficient improvement | fote machinery

There are different types of stone crushers in mining industry such as jaw crusher, cone crusher, impact crusher, and sand making machine. This article will tell you how to maintain the 4 types of rock crushers and how to efficicently improve their performance.

Many stone crusher operators have a common coception that is "don't-fix-it-if-it-isn't-broke". They may want to save cost at the begining while the consequence is that they have to spend more money on repair and face interuption on production. That's why I always say that preventive and predictive is very important for all types of stone crusher.

Preventive means that by making regular checklist and inspections to keep crushers in good condition. Maintenance checklist is usually set up on a daily (8 hours), weekly (40 hours), monthly (200 hours), yearly (2,000 hours). Only doing that, can you prolong the machine's life span and maximize its value in crushing process.

Predictive refers to mornitoring the condition of crusher when it is running. By some maintenance tools such as lubricating oil temperature sensors, lubricating oil filter condition indicator, you can timely draw the machine data so that making a comparison between the real situation and normal state. Predictive can help you find problem early then timely removing thers issues before demage occuring.

Ractive means that even if your crushers have got problems, as long as you adopt correct solutions to respond, you still can get your machine back to normal. Next, I'll introduce important skills to maintain your equipment.

The cone crusher in the secondary or tertiary crushing proccess often fractures medium-hard or hard rocks like pebble, quartz, granite, etc. It is easy to get premature crusher failure, if operators cannot make a correct and timely inspection and maintenance.

Mantle in moveable cone and concave is fixed cone. Due to directly contacting with rock materials, the two wear parts need frequent maintenance and protection. So operators have to know the preparations and maintaining skills.

The working principle of impact crusher is that the spinning rotor under the driving of the motor can genetate strong impact force which make blow bars crush stone material into small pieces. Then the crushed material would be thrown by hammers towards, which makes another crushing process "stone to stone".

The sand making machine is also known as the vertical shaft impact crusher. Its working mode is that the material falls vertically from the upper part of the machine into the high-speed rotating impeller. The impeller is one of the important parts of the sand making machine, and it is also the most vulnerable part.

After the materials collide with each other, they will be pulverized and smashed between the impeller for multiple times and discharged from the lower part. The materials crushed by the device have an excellent particle size and are suitable for aggregate shaping, artificial sand making and highway construction.

In the face of such a dazzling market, how to choose the production equipment suitable for users' actual needs among the numerous equipment brands of many machinery manufacturers is a big problem for many large and small enterprises. Here we list top 4 world's construction equipment manufacturers for you to choose:

As a leading mining machinery manufacturer and exporter in China, we are always here to provide you with high quality products and better services. Welcome to contact us through one of the following ways or visit our company and factories.

Based on the high quality and complete after-sales service, our products have been exported to more than 120 countries and regions. Fote Machinery has been the choice of more than 200,000 customers.

what is impact crusher|working principle, parts and types | quarrying & aggregates

what is impact crusher|working principle, parts and types | quarrying & aggregates

The impact crusher is a highly efficient coarse, medium and fine crusher for medium-hard and softer rocks. Whether in a quarry, mining or Construction waste recycling, the impact crusher can efficiently crush the stone, so that the particle shape, particle size distribution and cleanliness are in line with the strict standards of concrete and asphalt aggregate. Impact crushing equipment not only achieves first-class product quality but also a remarkable throughput.

When the stone falls into the working area of the blow bar (hammer), it is crushed by the impact of the blow bar on the high-speed rotating rotor, and is thrown to the apron for a second impact, and rebounds until the rotating blow bar (hammer) is hit again. This process is repeated until the material is crushed to the required size and discharged from the machine outlet.

Aiming at the problems of the previous generation of impact crushers in terms of crushing efficiency and processing capacity, the CI5X impact crusher optimizes the crushing cavity type, rotor speed and power curve, improves the crushing efficiency and crushing ratio, and makes the finished product The aggregate shape is further optimized, and the gradation curve is more reasonable.

The comprehensive processing capacity of the equipment is increased by more than 15% compared with the previous generation products, which can meet the requirements of high-grade concrete for the preparation of aggregates.

PFW impact crusher is a new type of high-performance hydraulic crusher developed with internationally advanced impact crusher technology. It is very suitable for coarse, medium and fine crushing of various soft and medium-hard minerals and rocks.

PF impact crusher adopts traditional impact crushing technology. After years of design optimization, it has more excellent performance and reliable use. It is the most common medium-hard and soft material fine crushing equipment.

The PF impact crushing cavity and rotor have been optimized in design, and the production capacity and finished product particle size have been improved compared with traditional impact crushing. The counterattack frame and rotor are mechanically adjusted, which is simple and reliable.

high efficiency impact crusher for stone crushing real-time quotes, last-sale prices

high efficiency impact crusher for stone crushing real-time quotes, last-sale prices

Impact crusher for stone crushingIntroduction OverviewThe crusher is mainly used in mining, construction, chemical, electric power, metallurgy and other industries, crushing compressive strength less than 250 MPa ore and limestone, slag, coke, coal, this machine is not suitable for crushing surface water than 8-10% ore or viscous material, its output size can be adjusted,various crushing specifications.ApplicationWidely used in mining, construction, chemical, electric power, metallurgy, railway, highway, energy, cement and other industries.Advantages1.The gap of counter plate and hammer is convenient to adjust, effective control feed size.2.Less power consumption, high efficiency.3.Keyless connection, easy maintenance, economical and reliable.4.Complete crushing functions,high productivity,small mechanical wear and high comprehensive benefits.5.Impact resistance, wear resistance, impact force.6.Simple structure, small size, light weight, production capacity,low production costs.7.Large feed inlet, high crushing chamber, adapt to the materials with high hardness.8.Crushing ratio is large,up to 40,reduce the cost of the equipment of the concentrator.Impact crusher working principle:The machine has a base, the box, after the shelves, the rotor, ratchet clamshell opening device and other components. Counter crusher work, the motor through the V-belt drive the rotor, the material on the rotor plate hammer high-speed impact and broken, and was thrown back to fight the brackets again broken, and then from the back surface back to the plate hammer area Broken, this process is repeated until the material is broken to the desired size.Material from the first feed port to the first crushing chamber, and then into the second crushing chamber, when the broken ore particle size is less than the gap between the hammer and the counterattack plate, the lower part from the machine, that is broken product.The machine on the shelves after the use of self-weight insurance device, when the non-broken objects into the crushing chamber, before and after the counter will be back, non-broken objects discharged from the body.Technical parameter tableModelSizeInlet sizeMaximum inletlengthProductivityPowerWeightmmmmmmt/hkwkgWPF-06076447403207701 WPF-080785070040073030015-3030-458130WPF-1008100080040083030030-5037-559800WPF-101010001000400108035050-8 WPF-121012501050400108035070-12 WPF-1212125012504001300350100-15 WPF-12 001430350130-18 WPF- 08601520500160-25 WPF- 08602030500300-35

The crusher is mainly used in mining, construction, chemical, electric power, metallurgy and other industries, crushing compressive strength less than 250 MPa ore and limestone, slag, coke, coal, this machine is not suitable for crushing surface water than 8-10% ore or viscous material, its output size can be adjusted,various crushing specifications.

The machine has a base, the box, after the shelves, the rotor, ratchet clamshell opening device and other components. Counter crusher work, the motor through the V-belt drive the rotor, the material on the rotor plate hammer high-speed impact and broken, and was thrown back to fight the brackets again broken, and then from the back surface back to the plate hammer area Broken, this process is repeated until the material is broken to the desired size.Material from the first feed port to the first crushing chamber, and then into the second crushing chamber, when the broken ore particle size is less than the gap between the hammer and the counterattack plate, the lower part from the machine, that is broken product.

The machine on the shelves after the use of self-weight insurance device, when the non-broken objects into the crushing chamber, before and after the counter will be back, non-broken objects discharged from the body.

high efficiency impact crusher for stone crushing produiction plant - best stone crusher plant solution from henan dewo

high efficiency impact crusher for stone crushing produiction plant - best stone crusher plant solution from henan dewo

Dewo machinery can provides complete set of crushing and screening line, including Hydraulic Cone Crusher, Jaw Crusher, Impact Crusher, Vertical Shaft Impact Crusher (Sand Making Machine), fixed and movable rock crushing line, but also provides turnkey project for cement production line, ore beneficiation production line and drying production line. Dewo Machinery can provide high quality products, as well as customized optimized technical proposal and one station after- sales service.

Dewo machinery can provides complete set of crushing and screening line, including Hydraulic Cone Crusher, Jaw Crusher, Impact Crusher, Vertical Shaft Impact Crusher (Sand Making Machine), fixed and movable rock crushing line, but also provides turnkey project for cement production line, ore beneficiation production line and drying production line.

Dewo machinery can provides complete set of crushing and screening line, including Hydraulic Cone Crusher, Jaw Crusher, Impact Crusher, Vertical Shaft Impact Crusher (Sand Making Machine), fixed and movable rock crushing line, but also provides turnkey project for cement production line, ore beneficiation production line and drying production line.

Professional Production High-Efficiency Ordinary Roller Crusher Plant Dewo machinery can provides complete set of crushing and screening line, including Hydraulic Cone Crusher, Jaw Crusher, Impact Crusher, Vertical Shaft Impact Crusher (Sand Making Machine), fixed and movable rock crushing line, but also provides turnkey project for cement ...

2,538 high efficiency roller crusher products are offered for sale by suppliers on Alibaba.com, of which crusher accounts for 23%, tire shredders accounts for 1%, and plastic crushing machines accounts for 1%. A wide variety of high efficiency roller crusher options are available to you, such as 1 year, 2 years, and 6 months.

tips for maintaining efficiency in crushing circuits - quarry

tips for maintaining efficiency in crushing circuits - quarry

Efficiency can be defined by the ratio of work done by a machine to the energy supplied to it. To apply what this means to your crusher, in your reduction process you are producing exactly the sizes your market is demanding.

In the past, quarries produced a range of single-size aggregate products up to 40mm in size. However, the trend for highly specified aggregate has meant products have become increasingly finer. Currently, many quarries do not produce significant quantities of aggregate coarser than 20mm; it is not unusual for material coarser than 10mm to be stockpiled for further crushing.

A jaw crusher is a compression-type of crusher. Material is reduced by squeezing the feed material between a moving piece of steel and a stationary piece. The setting or the space between those two pieces of steel controls the discharge size. The tighter the setting, the smaller the output size and the lower the throughput capacity. Jaw crushers are mainly used in primary crushing; they are rarely used as a secondary crusher.

As compression crusher, jaws generally produce the coarsest material because they break the rock by the natural inherent lines of weakness. A jaw crusher can be an excellent primary crusher when used to prepare rock for subsequent processing stages such as washing, classifying or a secondary crusher.

Try to choke-feed any compression-type crusher. Remember, we are using gravity and the weight of the material to push or force material through the chamber. Since in a compression machine the material breaks to fill the air pockets or voids in the chamber, a non-choke chamber will produce a slabbier output than a choke-fed chamber.

Jaw crushers are routinely choke-fed, as this maximises production capacity and ensures particles are uniformly broken. This promotes stone-on-stone crushing, which breaks up flaky or slabbier particles. If you are seeking fewer fines, trickle-feeding material into the jaw crusher could achieve this; however, this would have an adverse effect on particle shape and would also reduce throughput capacity, hindering the crushers efficiency.

Ideally, the feed rate should not be switched from choke to non-choke, as this would cause problems downstream at the secondary processing plant. In practice, many jaw crushers are fed in this intermittent fashion due to gaps in the delivery of feed material from the quarry. Jaw crusher feed should be pre-screened using a grizzly screen prior to crushing, to remove material finer than the closed side setting (CSS).

In practice, many jaw crushers are not fed to their design capacity; this is because the subsequent processing plant does not have sufficient capacity to handle the volume of material that would be produced if the jaw crusher were working to capacity.

Ideally, the reduction ratio of a jaw crusher should be 6:1. There are different ways to calculate reduction ratio, but the best way is something called the P80 factor. The reduction ratio is then calculated by comparing the input feed size passing 80 per cent versus the discharge size that passes 80 per cent. The finer the CSS, the greater the proportion of fines produced. The CSS of a jaw crusher helps determine the nip angle within a chamber, typically 19 to 23 degrees. Too large an angle causes boiling in the crushing chamber; this is where the jaw plates cannot grip onto the rock and it keeps slipping up and down, avoiding being crushed. The nip angle gets flatter as the machine is set tighter.

The settings on a jaw crusher are designed to produce material ideal for secondary crushing. The best particle shape is typically found in material about the same size as the CSS. Smaller sizes will contain a higher proportion of elongated particles because they have passed through the crusher without being touched. Larger sizes may also contain a higher proportion of elongated particles, as they are further from the CSS, which can cause bridging issues in downstream machines. The bottom line is that the best particle shape and performance comes from a choke-fed chamber.

Cone crushers and gyratory crushers are also compression-type machines that crush material between moving and stationary pieces of steel. The setting between the two pieces of steel controls the output. Though the chamber is round in shape, the moving piece of steel is not meant to rotate. Instead a wedge is driven around to create compression on one side of the chamber and discharge opening on the opposite side.

Cone crushers are used in secondary and tertiary roles as an alternative to impact crushers, when shape is an important requirement but the proportion of fines produced needs to be minimised. Even though the reduction in fines produced may be only a few percentage points, this could represent a significant amount of material in a large operation and, ultimately, increase an operations bottom line and profitability.

Increasing the CSS in an attempt to reduce the amount of fines produced may have the opposite effect; it may lead to a greater proportion of oversized material, which would need re-crushing in the remaining crushing circuits and would ultimately lead to a higher proportion of fines being produced. The further in the crushing process, the greater the amount of fines produced.

It is critical that a cone-type crusher be choke-fed to produce the best product shape and quality. It is not as important in a jaw, as material is not generally stockpiled after the jaw. Since the cone is in the secondary and tertiary stations, particle shape assisted by a choke-fed chamber is important, as it creates finished products in these stages.

Uniform distribution of feed material around the cone crusher inlet is a good practice. This allows production of a consistent product, as well as efficient, reliable operation of the crusher. Choke-feeding is important for cone crushers because it maintains a good particle shape by facilitating an inter-particle crushing action. Trickle feeding is not the best option because it increases the proportion of flaky material in the crusher product, hindering its efficiency.

It is a good rule to maintain about 10 to 15 per cent of material finer than the CSS in the feed to assist crushing action. More than 10 to 15 per cent will likely cause ring bounce due to the pressures in the chamber.

Pre-screening of the feed to remove the fines, especially in tertiary crushing, is a good practice; it helps to avoid packing of material in the chamber while maintaining an efficient, effective crushing action and increasing your crusher efficiency.

The liner profiles are designed for a range of product sizes, from extra coarse (EC) to extra fine (EF). The EF liner profile will result in the highest fines proportion for a given cone crusher. It is important to find the right liner for the feed gradation and desired product. If the liner is too large, feed material will drop too far in the chamber before being crushed. Too fine a liner will prevent material from entering the chamber at all.

Monitoring the crushing force as registered through the load on the crusher motors, as well as the pressure on the hydraulic mantle adjustment mechanism, will give forewarning of crusher packing problems before they affect your efficiency.

The finer the CSS, the greater the proportion of fines produced. The finer setting also lowers throughput volume. It is important to match the CSS of the crusher to the top size of the product to be produced. If the circuit is being closed at 25mm (1) to produce a 25mm minus product, the crusher should be set at, near or slightly below 25mm.

An impact crusher uses mass and velocity to break down feed material. First, the feed material is reduced as it enters the crusher with the rotating blow bars or hammers in the rotor. The secondary breakage occurs as the material is accelerated into the stationary aprons or breaker plates. Impact crushers tend to be used where shape is a critical requirement and the feed material is not very abrasive. The crushing action of an impact crusher breaks a rock along natural cleavage planes, giving rise to better product quality in terms of shape. The quality of these products makes them ideal for use in highly specified road, stone and concrete aggregate applications.

Establishing the proper rotational speed of the blow bars or hammers is critical for efficient reduction and production. Also, the angle of the feed plate that introduces the feed material to the rotor assists in the efficiency of the machine. Improper rotor penetration will result in decreased performance.

Size reduction in an impact crusher relies on energy being conveyed into the rock from the rotor, and it begins with your feed. The initial impact is responsible for more than 60 per cent of the crushing action, with the remainder made up of impact against an adjustable breaker bar and a small amount of inter-particle collision. This is why it is vitally important that the feed arrangement to an impact crusher ensures an even distribution of feed material across the full width of the rotor. This will allow for even distribution of energy into the feed material and uniform wear patterns, ensuring consistent product gradation and power consumption.

Establishing the proper rotational speed of the blow bars or hammers is critical for efficient reduction and production. Also, the angle of the feed plate that introduces feed material to the rotor assists in the efficiency of the machine. Improper rotor penetration will result in decreased performance.

Size reduction and, ultimately, the crusher setting are directly proportional to the rotor speed; it largely dictates how many fines are produced. Slower rotor speeds can be used as a means of reducing fines, but may result in a product with more oversize or return than is wanted. Slower rotor speeds are preferable as a means of minimising the wear on crusher components and for achieving less fines production and optimal product size.

The product grading from an impact crusher will change throughout the life of the wear parts, particularly the impact hammers or blowbars. As the profile of the hammer changes with increased wear, the product grading becomes coarser. Many modern impact crusher installations have a variable speed drive arrangement that allows an increase in the rotor speed to compensate for wear on the impact hammers.

In many impact crushers, a third curtain or crushing chamber can be added to increase reduction in every pass through the machine. This can be important in finer product applications, where the third chamber can provide the desired output gradation. A third chamber that increases the reduction will also increase the power needs and, normally, the wear cost.

Decreasing the gap between the hammers and impact curtain increases particle retention in the chamber. This increases the size reduction ratio; however, it also reduces efficiency throughput capacity and increases fines production.

Crushing efficiency begins with common crusher knowledge. Once you have a machine a jaw, cone/gyratory or impact crusher how you feed it and how you set it will affect its efficiency. By taking many of the steps outlined above to achieve the best crushing outcome, producers can reduce the amount of fines they produce and save more dollars for their pockets.

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