Introduction to Industrial Crushers

A crusher is a machine designed to reduce large iron ore into smaller rocks, gravel, or rock dust. Crushers may be used to reduce the size, or change the form, of waste materials so they can be more easily disposed of or recycled, or to reduce the size of a solid mix of raw materials (as in iron ore), so that pieces of different composition can be differentiated. Crushing is the process of transferring a force amplified by mechanical advantage through a material made of molecules that bond together more strongly, and resist deformation more, than those in the material being crushed do. Crushing devices hold material between two parallel or tangent solid surfaces, and apply sufficient force to bring the surfaces together to generate enough energy within the material being crushed so that its molecules separate from (fracturing), or change alignment in relation to (deformation), each other.

Application of Crushers
Crusher plants are widely used for the following industries and sectors:

Agro Based industries Animal (Cattle) Feed plants Ayurvedic and Herbal plants Cement plants Ceramic Plant Chemical Industries Coconut Shell Plant Dal Mills Salt Plant Mines and Minerals Mini Cement Plants Plaster of Paris Plant Poultry Feed Plant Quarry Plant Refractory Plant Stone quarry

Types of crushers:1. Jaw crusher Introduction:A jaw crusher uses compressive force for breaking of particle. This mechanical pressure is achieved by the two jaws of the crusher of which one is fixed while the other reciprocates. A jaw or toggle crusher consists of a set of vertical jaws, one jaw is kept stationary and is called as fixed jaw while the other jaw, called as swing jaw, moves back and forth relative

to it, by a cam or pitman mechanism. Application of Jaw Crusher is one of the most
popular stone crusher in the world, Jaw Crusher is ideally suitable for primary and secondary crushing. The highest anti-pressure strength of crushed material is 320MPa. It is widely used in mining, metallurgy, construction, highway, railroad, and chemistry industries and etc. Many models are available according to your different fineness requirements.

Working principle:
Its working principle is: Motor drives belt and belt pulley, makes moving jaw up and down through eccentric shaft. When the moving jaw is up, the angle between lining plate and moving jaw becomes large, and this will push moving jaw plate close to the fixed jaw plate. During this process, the material is crushed and ground, thus the crushing will be done. When the moving jaw is down, the angle between lining plate and moving jaw becomes small, the moving jaw plate will leave the fixed jaw plate on account of the effect of pulling bar and spring, and then the crushed material will be discharged from the lower opening of the crushing room. With the motor continuously rotating and the material periodically crushed and discharged by the crusher, the mass production can be realized

Jaw crushers are classified on the basis of the position of the pivoting of the swing jaw 1. Blake crusher-the swing jaw is fixed at the upper position 2. Dodge crusher-the swing jaw is fixed at the lower position 3. Universal crusher-the swing jaw is fixed at an intermediate position

2. Gyratory crusher:A gyratory crusher is similar in basic concept to a jaw crusher, consisting of a concave surface and a conical head; both surfaces are typically lined with manganese steel surfaces. The inner cone has a slight circular movement, but does not rotate; the movement is generated by an eccentric arrangement. As with the jaw crusher, material travels downward between the two surfaces being progressively crushed until it is small enough to fall out through the gap between the two surfaces. A gyratory crusher is one of the main types of primary crushers in a mine or ore processing plant. Gyratory crushers are designated in size either by the gape and mantle diameter or by the size of the receiving opening. Gyratory crushers can be used for primary or secondary crushing. The crushing action is caused by the closing of the gap between the mantle line (movable) mounted on the central vertical spindle and the concave liners (fixed) mounted on the main frame of the crusher. The gap is opened and closed by an eccentric on the bottom of the spindle that causes the central vertical spindle to gyrate.

3. Cone crusher Introduction:

A cone crusher is similar in operation to a gyratory crusher, with less steepness in the crushing chamber and more of a parallel zone between crushing zones. A cone crusher is suitable for crushing a variety of mid-hard and above mid-hard ores and rocks.

Working principle:A cone crusher breaks rock by squeezing the rock between an eccentrically gyrating spindle, which is covered by a wear resistant mantle, and the enclosing concave hopper, covered by a manganese concave or a bowl liner. As rock enters the top of the cone crusher, it becomes wedged and squeezed between the mantle and the bowl liner or concave. Large pieces of ore are broken once, and then fall to a lower position (because they are now smaller) where they are broken again. This process continues until the pieces are small enough to fall through the narrow opening at the bottom of the crusher. Advantage 1. Reliable construction, 2. High productivity, 3. Easy adjustment and 4. Lower operational costs. The spring release system of a cone crusher acts an overload protection that allows tramp to pass through the crushing chamber without damage to the crusher.

5. Impact crusher
Introduction:-

Impact crushers involve the use of impact rather than pressure to crush material. Impact Crushers are used in both primary and secondary crushing applications of
aggregate, and in recycle crushing of reinforced concrete, asphalt and other construction and debris. VIPEAK is a reliable supplier of Impact Crusher with new design.

Working principle:
When the Impact Crusher works, the motor drives the rotor rotate of the Impact Crusher with high speed, on the rotor where installed the hammers. When the materials get into the area which the hammers affect, under the impact function of the hammer at a high speed, the materials are thrown to the impact device above the rotor continuously. And then the materials are rebounded from the impact liner to the area where the hammers effects for being re-crushed. The materials from large to small all to be crushed at the impact chamber repeatedly. The process won't stop till the material are crushed to the required size and then discharged from outlet of the Impact Crusher. Characteristics of Impact Crusher: Excellent cubic final products Special structure Non-key connection High chrome hammer Durability in long time simplicity in operation Easy adjustment, high reduction ration Good performance and high reliability

There are two types of impact crushers: 1. Horizontal shaft impactor (HSI) / Hammer mill The HSI crushers break rock by impacting the rock with hammers that are fixed upon the outer edge of a spinning rotor. HSI machines are sold in Stationary, trailer mounted and crawler mounted configurations. HSI's are used in recycling, hard rock and soft materials. In earlier years the practical use of HSI crushers is limited to soft materials and nonabrasive materials, such as limestone, phosphate, gypsum, weathered shales, however improvements in metallurgy has changed the application of these machines. 2. Vertical shaft impactor (VSI) VSI crushers use a different approach involving a high speed rotor with wear resistant tips and a crushing chamber designed to 'throw' the rock against. The VSI crushers utilize velocity rather than surface force as the predominant force to break rock. In its natural state, rock has a jagged and uneven surface. Applying surface force (pressure) results in unpredictable and typically non-cubical resulting particles. Utilizing velocity rather than surface force allows the breaking force to be applied evenly both across the surface of the rock as well as through the mass of the rock. Rock, regardless of size, has natural fissures (faults) throughout its structure. As rock is 'thrown' by a VSI Rotor against a solid anvil, it fractures and breaks along these fissures. Final particle size can be controlled by 1) the velocity at which the rock is thrown against the anvil and 2) the distance between the end of the rotor and the impact point on the anvil. The product resulting from VSI Crushing is generally of a consistent cubical shape such as that required by modern SUPERPAVE highway asphalt applications. Using this method also allows materials with much higher abrasiveness to be crushed than is capable with an HSI and most other crushing methods. VSI crushers generally utilize a high speed spinning rotor at the center of the crushing chamber and an outer impact surface of either abrasive resistant metal anvils or crushed rock. Utilizing cast metal surfaces 'anvils' is traditionally referred to as a "Shoe and Anvil VSI". Utilizing crushed rock on the outer walls of the crusher for new rock to be crushed against is traditionally referred to as "rock on rock VSI". VSI crushers can be used in tatic plant set-up or in mobile tracked equipment.