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hsi vs vsi crushers

what is a vertical shaft impactor (vsi) primer? | stedman machine company

what is a vertical shaft impactor (vsi) primer? | stedman machine company

All roads, you might say, lead to the Vertical Shaft Impactor (VSI) because these crushers make it possible to create roadways and just about everything else. Francis E. Agnew of California patented one of the first Vertical Shaft Impactors in 1927. His configuration stacked three VSIs atop each other to produce sand, thus starting the VSI evolution.

Today, VSI crushers and the folks who rely on them have produced many configurations to include everything from the addition of cascading material into the crushing chamber, to air swept separation of lighter product. One version suspends the shaft from above like a sugar centrifuge. Its also one of the most feature-patented crushers, so some of the things mentioned here might be unique to a single manufacturer. VSIs apply a large amount of energy to crush material and thats why its one of the most versatile crusher configurations today.

When it comes to producing materials such as aggregate for road making, VSI crushers use a high-speed rotor and anvils for impact crushing rather than compression force for the energy needed for size reduction. In a VSI, material is accelerated by centrifugal force by a rotor against the outer anvil ring, it then fractures and breaks along natural faults throughout the rock or minerals. The product is generally of a consistent cubical shape, making it excellent for modern Superpave highway asphalt applications. The rotor speed (feet per minute) controls final particle size.

The VSIs high cubical fracture percentage maximizes first-pass product yield and produces tighter particle size distribution. It has a high-throughput capacity ideal for beneficiation (elimination of soft material). Properly configured the VSI accepts highly abrasive materials. It has simple operation and maintenance. You can quickly change product size by changing rotor speed or cascade ratio. Some models have reversible wear parts to reduce downtime. The VSI typically has low operating costs even in high-moisture applications because of reduced energy costs and low wear cost per ton.

There are some feed size limitations with a VSI because of the small feed area available in the center of the rotor. Tramp material in the feed such as gloves, tools, etc. can cause problems with imbalance. The high RPM and HP require careful balance maintenance such as replacing shoes on both sides of the rotor at the same time. High wear part cost may be a problem for some hard abrasive materials, but the VSI may still be the best option.

Major limestone applications are for Superpave asphalt aggregates, road base, gravel, sand and cement. Industrial uses include: corundum, corundite, ferro silicon, glass, refractories, silicon carbide, tungsten carbide and zeolite. Mining applications include: bauxite, burnt magnesite, iron ore, non-ferrous metal ore, perlite and trona sulfate. VSIs are excellent for everything from abrasive materials to waste and recycling applications.

Feed size and characteristics will affect the application of a VSI. The feed size is limited by the opening in the center of the rotor. Normally less than 5-inch material is desired, but very large VSIs can handle up to 12-inch feed. Another feature that will affect application is moisture, which can make the feed sticky. Required production capacity is the final limiting criteria. Large primary horizontal shaft impactors can output up to 1600 TPH and more. 1000 TPH is about the maximum for a VSI because of the limiting motor size and the rising G-force of a high-speed rotor, which is calculated by multiplying the radius times the square of the RPM.

Shoe configurations are many: rock on rock, groups of rollers, special tip wear parts and many others. The metallurgy of the shoes is also highly varied. Rotors can have three to six shoes. The number of shoes is typically governed by the diameter of the rotor. The larger the diameter rotor, the more openings are possible. Computational Fluid Dynamics (CFD) mathematical models are utilized to simulate the flow and collision forces to reveal solutions for lower wear cost, consistent final product, and higher energy efficiency.

The material to be crushed is fed into the center of an open or closed rotor. The rotor rotates at high rpm, accelerating the feed and throwing it with high energy into the crushing chamber. When the material hits the anvil ring assembly, it shatters, and then the cubical shaped product falls through the opening between the rotor and the anvil and down to the conveyor below.

The typical VSI is fed, from above, into the center of its rotor. The material is then flung across an open void to the crushing chamber. It then impacts the outer anvil ring. This crushing action imparts very high energy to the material and is very effective on most types of material. It gives a very uniform and consistent grade of product.

In cascade feeding, material bypasses the rotor and enters the crushing chamber from above. Its called cascade feeding because as material fills up a large feed bowl, with an outer diameter larger than the outer diameter of the rotor, it spills over the side and falls into the crushing chamber from above, bypassing the rotor. The effect of increasing feed through cascade is similar to slowing the rotor. Cascade feeding in amounts up to 10 percent may have no effect on particle size distribution or quality. The product gradation curve and product shape will change, if an increased amount of cascade feeding is used.

The VSI features multiple rotor/anvil configurations for various applications. From open or enclosed rotors to the tubular rotor, each machine is configured for their unique application. In many cases the rotor table, rotor assemblies, anvil ring or rock shelf are interchangeable, allowing maximum application flexibility.

The open top metal rotor is good for large feed or medium to very hard material, but it will work best for softer materials. It can handle medium abrasive, dry or wet, but not sticky materials. High reduction ratios are common, which are excellent for sand and gravel production in closed loop systems. Shoe shape can change the production size range. A straight shoe face design produces finer product, and a curved shoe face design produces coarser material.

The tubular rotor creates higher tip-speeds, which increases first pass yield with tighter particle size distribution and also reduces the recirculation loads. One unique feature is that the rotor rotation is reversible, allowing wear on both sides of the tube. Rotating the tube itself one-quarter turn also doubles the wear.

Any time the material or rock is used as an impact wear surface the term autogenous is used. Putting a top on the rotor table and shoes allows autogenous use. During operation of the VSI, a bed of material can be designed to build up inside the rotor against each of the shoe wall segments. The bed, which is made up of material that has been fed to the rotor, extends to a wear tip. The bed protects the shoe wall segment from wear.

Concerning the rock shelf anvil, it forms a near vertical wall of material upon which the accelerated material impacts. Rock-on-rock crushing reduces maintenance but can require up to 30 percent of material recirculation before meeting size requirements. Also, the rock shelf anvil absorbs energy that could otherwise be used for breaking, which may reduce efficiency. More RPM may be needed to achieve the same result as a solid metal anvil.

Good for medium abrasive materials, rock-on-rock configurations of either or both rotor and anvil may produce consistent material with low-wear cost and can handle wet but not sticky conditions. Reduction ratios from 2:1 to 5:1 can be expected. Its widely used for quarried materials, such as sand and gravel.

The VSI is one of the most versatile crushers available on the market today. Even with some limitations, like feed size and output capacity, VSI features have been and continue to be developed to maximize first-pass yields and lower operating costs. If you test your process on full-scale equipment before choosing your VSI, you wont be disappointed.

Stedman Machine Company works closely with its customers to determine the best, most cost-effective, efficient size reduction method and equipment for specific applications. Stedmans line of equipment includes: Cage Mills, Grand Slam and Mega Slam Horizontal Shaft Impactors, V-Slam Vertical Shaft Impactors, Hammer Mills, Aurora Lump Breakers, Micro-Max and Vertical Roller Mill Air Swept Fine Grinders. Stedman operates a complete testing and toll processing facility staffed by experienced technicians with full-scale equipment, allowing customers to witness accurate crushing test results, predicted output capacities and processing data. Support services include system design and 24-hour parts and service.

impact crusher | description | advantages | types of impact crusher | engineering intro

impact crusher | description | advantages | types of impact crusher | engineering intro

The word impact makes sense that in this particular type of crusher some impaction is being used for crushing of rocks. In normal types of crusher pressure is generated for the crushing of rocks. But, impact crushers involve an impact method.

There is a hopper one side that takes the crushing material into the machine. All material is carried only within a cage. This cage has an opening on the end, bottom and on the side. These openings help in escaping the pulverized material from the impact crusher. Normally such type of crusher is used for crushing of materials that are not very hard say soft material and materials that are non-abrasive. For example limestone, coal, gypsum, seeds etc.

Horizontal shaft impactor (HSI) crusher consists of hammers that are fixed to the spinning rotor. Hammers are utilized for the breaking of these rocks. Normally horizontal shaft impactor crusher is used for soft materials and materials like gypsum, phosphate, limestone and weathered shales.

Working principle of vertical shaft impactor is totally different than horizontal shaft impactor. It has a high speed rotor with wearing resistant tips and main chamber (crushing chamber) is designed in such a way so that speed rotor throw the rocks against the high crushing chamber. In vertical shaft impactor crusher predominant force is the velocity of speed rotor.

Rock from ores has an irregular uneven shape. If crushers that used pressure force is used then it results in unpredictable and even more uneven, jagged shape particles. Therefore, use of VSI crusher results in more cubical and even shapes particles. This is so, because vertical shaft impactor crusher utilizes the velocity force that is applied evenly to the surface and the mass of rock.

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vsi crushers - remco

vsi crushers - remco

REMco Vertical Shaft Impactors are typically used in the third or fourth stage of crushing circuits. Feed rates are from 15 to 1500 TPH. Machine drive powers range from 50hp to 1500hp and feed sizes can be from 4 (100 mm) to 1/8" (2.5 mm) or less. Seven models in over 40 configurations ensure that the VSI you buy is suited to your crushing needs.

Do you need sand? Ever since man began to build, he has sought quality sand. Sand that has rounded particles, sand that has a full range of well-graded sizes, sand that finishes smoothly, sand that gives strength and beauty to what man builds.

As natural sand deposits are depleting, the demand for man-made sand has increased. Our impact crushers are proven to be the most efficient method for size reduction to manufacture sand. Prior to the REMco SandMax, a wide range of crusher types had been applied to the task with limited success. The challenge of creating a quality product, in specifications, with high durability, cubical particle shape, and with the desired F.M. (fineness modulus) has caused many crusher failures.

High-strength sand comes from hard rock, and hard rock is where the REMco SandMaxbeats all other crushing machines. For versatility of use, net tons of product, total run cost, ease of installation, smoothness of operation, reliability, and hassle-free performance, the REMco SandMaxis superior to all others.

Producing quality specification sand requires more than a crusher. It requires knowledge, a well-designed material processing circuit, specialized rotors, and the willingness to understand that sand production is more than rock crushing. At REMco, we can teach you how to make your sand.

REMco VSISandMaxcrushers are fully autogenous vertical shaft impact crushers designed to operate as third or fourth stage crushers in the processing of all types of rock, ores, and minerals. SandMax crushers can be operated in either open-circuit or closed-circuit. Closed-circuit operation is recommended to achieve the lowest net operating cost and the highest production of any given size below 1/2" (13 mm).

Hard Rock? Impact Crushing has been proven to be the most efficient method of size reduction when processing rocks, ores, and/or minerals. The reason? It's the best way to transfer energy from the drive motors to the material being reduced.

Hard Rock? Impact Crushing has been proven to be the most efficient method of size reduction when processing rocks, ores, and/or minerals. This is because it's the best way to transfer energy from the drive motors to the material to effectively reduce its size. Impact crushers have fewer moving parts, and less mechanical loss when compared to compression machines like cone crushers.

In the past, the limits on impact crushers have been their high cost to operate when the materials are hard and abrasive. Historically, hard rocks such as granites, quartzite, and other materials with high abrasives content have caused severe wear on the crushing members of vertical shaft impact crushers, making them immensely expensive to operate.

REMco's innovation of combining heavy-duty vertical shaft impactor design with an autogenetic (rock-lined) crushing chamber and rotors has lowered the wear parts operating cost of the RockMaxto a level equal to or less than any fine head cone crusher. This rate is for cost per net ton of finished product regardless of material or product tonnage required.

REMco VSIRockMaxCrushers are autogenous vertical shaft crushing machines designed to operate as third stage crushers in the processing of all types of rock, ores, and minerals.RockMaxcrushers can operate in either open or closed-circuit. Closed-circuit operation is recommended to achieve the lowest net operating cost, best particle shape, and the highest production.RockMaxcrushers are intended for producing crushed products between 1 1/2 to 3/8 / 40mm to 10mm.

For less abrasive stones and minerals, the Swing Top / Anvil Ring Vertical Shaft Impact Crusher, or ST/AR VSI, is the way to go. Theyre a variation of the REMco SandMax and RockMax series, but specialized.

These machines feature the same heavy-duty design and components, as well as our new bearing cartridge and main shaft design, but with the addition of our innovative, reversible anvil design that lets you use the most of the wear iron in the anvil. There are several anvil shapes, each suitable for a broad range of applications. This feature provides maximum crushing efficiency when the anvils are new and concentrates the wear on half of the anvil face. This raises the percent of wear iron in use and extends the life of the anvil and the efficiency of the crusher.

By simply rotating the anvil you are provided with an entirely new crushing face on the same anvil, thus allowing you to maintain maximum crushing efficiency during the entire life of the anvil as opposed to just when its brand new. This innovation also reduces scrap loss. REMco ST/ARs are incredibly versatile too. They can easily be converted from the rock-on-anvil crusher to a fully autogenous, rock-on-rock chamber.

REMcoST/ARVSI crushers are rock-on-anvil vertical shaft crushing machines designed to operate as second, third or fourth stage crushers for processing soft to medium/hard rocks, ores or minerals that contain less than 15% abrasives (silica, alumina, and iron). Maximum feed size is 6 (150 mm) and product sizes can be from 1 1/2 (40 mm) to minus 6 mm.

OreMax units are used as pre-milling machines before ball mills to eliminate rod mills. They are also used to relieve the crushing load of overworked older cone crushers and produce a finer product for the grinding stages in metal mining and cement operations.

The REMcoOreMaxVSI crushers are based on the larger size models. TheOreMaxdesignation applies to crushers capable of 400 hp and above to the limit of 1,500 hp. These machines are of extra-heavy-duty construction and designed for the severe demands of multiple shifts, and continuous service. The bearings, shafts and general construction of these crushers are heavier than all other VSI crushers.

Complimenting theOreMax construction are REMcos unique CONQUEROR Rotors, built with tungsten carbide wear parts, and REMcos patented ARC-tip which provides rotor service intervals of 1,000 hours or more between changes. OreMaxunits are supplied standard withSmartBox, machine management, oil/lubrication, and machine safety systems.

TheOreMaxis available as a fully-autogenous, semi-autogenous or anvil type crusher. The anvil type units are designated asOreMax-ST/ARmachines. TheOreMaxPre-mill units are designed for extra-fine crushing and grinding.

Maximum recommended feed size will vary depending on the type, hardness, and shape of rock or ore being crushed. Typically, maximum feed size is limited to 4 (100 mm) depending on the size of the machine, connected drive power, and reduction ratio. REMco OreMaxunits can be used as pre-milling machines before ball mills to eliminate rod mills. Another use forOreMax units is to relieve the crushing load of overworked, older cone crushers and produce a finer product for the grinding stages in metal mining and cement operations.

REMco custom builds specialty large machines when the application requires very high capacities. These machines are designated asSuperMaxModels and are configured in any one of the four basic designs,SandMax,RockMax,OreMax, andST/AR.

These crushers are generally powered with two motors in dual drive configurations. TheSuperMaxModels operate at 1,000 HP to a maximum of 1,500 HP. Like all other REMco crushers, SuperMax machines perform at the highest level of excellence and stand the test of time. REMco is still servicing machines that have been running since 1998, and we'll work to keep them running for years to come.

SuperMax Models come standard with multiple accessories like the oil/lubrication system, a spare rotor, installation kits, and the REMco SmartBox system. Additionally, theSuperMaxcan include any number of special or unique features as requested by the customer. TheSuperMaxis usually applied in the third or fourth stage crushing application where large quantities of product are required.

Get your hands on the ultimate crushing machine management system! The SmartBox (System Monitoring And Recording Technology) is the future of crusher operating monitoring systems. It will keep you up to date on your performance and "health" of your crushers.

The REMco VSI SmartBox crusher touchscreen controller provides consistent real-time information about the machines operating performance.SmartBox monitors and records all critical elements including:

REMco VSIRockMaxCrushers are autogenous vertical shaft crushing machines designed to operate as third stage crushers in the processing of all types of rock, ores, and minerals.RockMaxcrushers can be operated in either open or closed-circuit. Closed-circuit operation is recommended in order to achieve the lowest net operating cost, best particle shape, and the highest production.RockMaxcrushers are intended for producing crushed products between 1 1/2 to 3/8 / 40mm to 10mm.

Application is the key to successful VSI installation and operation. Rock and mineral deposits vary widely from site to site, country to country and around the world. Crushing plants, circuit variations, and product requirements are infinite.

REMco understands that the greatest success comes when the users and the VSI manufacturer fully understand the crushing task. While most crusher manufacturers make a limited number of VSI models in fixed configurations, REMco manufactures a variety of them. We make a multitude of configurations for each type to maximize the machinery's performance and production rate while minimizing the wear and tear to the machine as well as saving energy costs; all with easy maintenance.

vertical shaft impactors - vsi crushers | stedman machine company

vertical shaft impactors - vsi crushers | stedman machine company

V-Slam VSI Models from Stedman are vertical shaft impactors for all your coarse-to-fine crushing needs. VSI crushers offer significant savings over higher-priced competitive crushers. The V-Slam, with its low horsepower per ton of throughput, minimizes operating costs.

Our vertical shaft impactors featuremultiple rotor configurations for various applications. From open and enclosed rotors to the Stedman Patented Tubular Rotor, each machine is configured to provide customers exactly what is needed for their unique application.

The new Patented Tubular Rotor provides many benefits over the standard shoe and anvil designs as well as rock-shelf applications. The easily replaceable and indexable rotor tubes, cut your total operating cost and maintenance time in half, making V-Slam the easiest VSI crusher to maintain and one of the best impact crushers on the market.

Stedman's testing facilities provide real-world conditions to view your materials being processed. Test out a range of different size reduction methods, saving you both time and money when selecting the proper size reduction method.

Why Stedman? Delivering equipment and service you deserve For nearly two centuries, Stedman Machine Company has produced quality, reliable and durable size reduction and industrial crushing equipment. Stedman has expert field service and installation technicians ready to assist with all maintenance and equipment commissioning needs. Unsurpassed industry experience operating since 1834 State-of-the-art equipment testing facilities Dedicated, professional staff Parts and service available 24 hours a day

For nearly two centuries, Stedman Machine Company has produced quality, reliable and durable size reduction and industrial crushing equipment. Stedman has expert field service and installation technicians ready to assist with all maintenance and equipment commissioning needs.

Stedman Machine is a leading manufacturer of VSI crushers with the capability to provide customer service across the globe. Our experienced team will work with you to create the best impact crusher system to make your processes the most efficient. Call us for more information!

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