crushers - all crusher types for your reduction needs - metso outotec

crushers - all crusher types for your reduction needs - metso outotec

All rock crushers can be classified as falling into two main groups. Compressive crushers that press the material until it breaks, and impact crushers using the principle of quick impacts to crush the material. Jaw crushers, gyratory crushers, and cone operate according to the compression principle. Impact crushers, in turn, utilize the impact principle.

As the name suggest, jaw crushers reduce rock and other materials between a fixed and a moving jaw. The moving jaw is mounted on a pitman that has a reciprocating motion, and the fixed jaw stays put. When the material runs between the two jaws, the jaws compress larger boulders into smaller pieces.

There are two basic types of jaw crushers: single toggle and double toggle. In the single toggle jaw crusher, an eccentric shaft is on the top of the crusher. Shaft rotation causes, along with the toggle plate, a compressive action.

The chewing movement, which causes compression at both material intake and discharge, gives the single toggle jaw better capacity, compared to a double toggle jaw of similar size. Metsos jaw crushers are all single toggle.

Gyratory crushers have an oscillating shaft. The material is reduced in a crushing cavity, between an external fixed element (bowl liner) and an internal moving element (mantle) mounted on the oscillating shaft assembly.

The fragmentation of the material results from the continuous compression that takes place between the liners around the chamber. An additional crushing effect occurs between the compressed particles, resulting in less wear of the liners.

Cone crushers resemble gyratory crushers from technological standpoint, but unlike gyratory crushers, cone crushers are popular in secondary, tertiary, and quaternary crushing stages. Sometimes, however, the grain size of the processed material is small enough by nature and the traditional primary crushing stage is not needed. In these cases, also cone crushers can carry out the first stage of the crushing process.

Cone crushers have an oscillating shaft, and the material is crushed in a crushing cavity, between an external fixed element (bowl liner) and an internal moving element (mantle) mounted on the oscillating shaft assembly.

An eccentric shaft rotated by a gear and pinion produces the oscillating movement of the main shaft. The eccentricity causes the cone head to oscillate between open side setting and closed side setting discharge opening.

The fragmentation of the material results from the continuous compression that takes place between the liners around the chamber. An additional crushing effect occurs between the compressed particles, resulting in less wear of the liners. This is called interparticular crushing also.

Depending on cone crusher, setting can be adjusted in two ways. The first way is for setting adjustment to be done by rotating the bowl against the threads so that the vertical position of the outer wear part (concave) is changed. One advantage of this adjustment type is that liners wear more evenly.

To optimize operating costs and improve the product shape it is recommended that cone crushers are always be choke fed, meaning that the cavity should be as full of rock material as possible. This can be easily achieved by using a stockpile or a silo to regulate the inevitable fluctuation of feed material flow. Level monitoring devices detect the maximum and minimum levels of the material, starting and stopping the feed of material to the crusher, as needed.

Impact crushers are traditionally classified to two main types: horizontal shaft impact (HSI) crushers and vertical shaft impact (VSI) crushers. These different types of impact crushers share the crushing principle, impact, to reduce the material to smaller sizes, but features, capacities and optimal applications are far from each other.

Horizontal shaft impact (HSI) crushers are used in primary, secondary or tertiary crushing stage. HSI crushers reduce the feed material by highly intensive impacts originating in the quick rotational movement of hammers or bars fixed to the rotor. The particles produced are then further fragmentated inside the crusher as they collide against crusher chamber and each other, producing a finer, better-shaped product.

VSI crusher can be considered a stone pump that operates like a centrifugal pump. The material is fed through the center of the rotor, where it is accelerated to high speed before being discharged through openings in the rotor periphery. The material is crushed as it hits of the outer body at high speed and due to rocks colliding against each other.

Selecting optimal crushing equipment can be difficult. Luckily there are tools and software available that simplify weighting different options and help in making decisions. The backbone of all these analyzes are careful calculations that take into account the capabilities and constraints of different crushers and operational requirements.

Every crushing site and operation is different, and theoptimal results are normally obtained by combining theoretical conclusions with practical experience of different materials, operational conditions, maintenance needs, and economic aspects of various alternatives.

Below are some key issues listed according to crushing stages in brief. While defining the best technical solution for your requirements, its good to remember that many crushers are available not only as stationary but also asmobileorportableversions in case you prefer to move or transport your crusher at the production site or between sites regularly.

If you are interested in more detailed analyzes tailored just for your crushing operations, please contact Metso experts. We have practical experience of thousands of different crushing applications around the world, and we are happy to help in finding the equipment that best fits your needs.

The main purpose of a primary crusher is to reduce the material to a size that allows its transportation on a conveyor belt. In most crushing installations a jaw crusher takes care of primary crushing. Plants with very high capacities that are common in mining and less popular in aggregates production, normally use a primary gyratory crusher. When the processed material is easy to crush and not very abrasive, an impact crusher may be the best choice for primary crushing.

One of the most important characteristics of a primary crusher is its capacity for accepting feed material without bridging. A large primary crusher is, naturally, more expensive than a smaller one. Therefore, the investment cost calculations for primary crushers are compared together against the total costs of primary stages, including quarry face clearing, blasting, and drilling costs. In many cases, dump trucks transport the rock to a stationary primary crusher. This may be an expensive solution. Amortization, fuel, tires, and maintenance costs can be included when the vehicles are in high demand. In modern aggregates operations, the use of mobile primary crushers that can move alongside the rock face is, in many cases, the most economical solution.

In terms of the size of the feed opening, the client gets a better return on investment when the primary crusher is a jaw crusher. That means less drilling and blasting because the crusher accepts larger boulders. The disadvantage of this type of crusher, when high capacity is required, is the relatively small discharge width, limiting the capacity as compared with the discharge circuit of a gyratory crusher. Jaw crushers are mainly used in plants producing up to approximately 1600 t/h.

The primary gyratory crusher offers high capacity thanks to its generously dimensioned circular discharge opening (which provides a much larger area than that of the jaw crusher) and the continuous operation principle (while the reciprocating motion of the jaw crusher produces a batch crushing action). The gyratory crusher has no rival in large plants with capacities starting from 1200 t/h and above. To have a feed opening corresponding to that of a jaw crusher, the primary gyratory crusher must be much taller and heavier. Also, primary gyratories require quite a massive foundation.

The primary impact crusher offers high capacity and is designed to accept large feed sizes. The primary impact crushers are used to process from 200 t/h up to 1900 t/h and feed sizes of up to 1830 mm (71") in the largest model. Primary impact crushers are generally used in nonabrasive applications and where the production of fines is not a problem. Of all primary crushers, the impactor is the crusher that gives the best cubical product.

If the intermediate crushing is done with the purpose of producing railway ballast, the quality of the product is important. In other cases, there normally are no quality requirements, except that the product be suitable for fine crushing.

Due to their design, cone crushers are generally a more expensive investment than impactors are. However, when correctly used, a cone crusher offers lower operating costs than a conventional impact crusher. Therefore, clients crushing hard or abrasive materials are advised to install cone crushers for the final crushing and cubicising stage.

Cone crushers can in most cases also give a good cubic shape to fine grades. They can be adapted to different applications. This is an important factor, as client-specific needs often change during a crushers lifetime.

The conventional type has horizontal shaft configuration, known as HSI. The other type consists of a centrifugal crusher with vertical shaft, generally known as VSI. Impactor operation is based on the principle of rapid transfer of impact energy to the rock material. Impactors produce cubic products, and they can offer high reduction ratios as long as the feed material is not too fine. This means that in certain cases it is possible to use a single impact crusher to carry out a task normally done in several crushing stages using compressing crushers (i.e., jaw, gyratory, and/or cone crushers). Impactors are mostly used for nonabrasive materials.

Conventional horizontal-shaft impact crushers are available in various sizes and models, from high-capacity primary crushers for large limestone quarries to specially designed machines for the crushing of materials such as slag.

There are two main categories of VSI crushers machines with impact wear parts around the body and machines that use a layer of accumulated material. The first type is in many respects similar to the conventional impactor with horizontal shaft and rotor. The second type became quite popular in the past decade and is known as the Barmac crusher. The difference between a conventional impactor and a VSI of the Barmac type is that the latter offers lower operating costs, but its reduction ratio is lower also. In a Barmac VSI, the material undergoes an intense rock-on-rock crushing process. In the other crushers, most of the reduction is done by the impact of stone against metal.

Customers operating old, rebuilt, or expanded plants often have problems with the shape of the product. In these cases, the addition of a Barmac VSI in the final crushing stage offers a solution to product shape problems.

The same applies to many mobile crushing units. As the number of crushing stages is normally small with this type of plant, it is almost impossible to obtain a good product shape unless the rock is relatively soft and thus more suited for the production of cubic product. A centrifugal crusher in the final stage can help to solve the problem.

Get the maximum potential out of your size reduction process to achieve improved crushing performance and lower cost per ton. By using our unique simulation software, our Chamber Optimization experts can design an optimized crushing chamber that matches the exact conditions under which you operate.

primary crushing plants - takraf gmbh

primary crushing plants - takraf gmbh

Primary crushing plants can be equipped with gyratory crushers, jaw crushers, twin-shaft sizers, double-roll crushers, impact crushers or hammer crushers, depending on material properties and required throughputs.

We areable to provide mobile, semi-mobile or stationary plants and work together with our clients to choose the most suitable machine type depending on the mineral deposit, mine plan and mining method.

TAKRAF supplies fully-mobile crushing plants equipped with crawlers, wheels or walking mechanisms. Fully mobile crushing plants are directly fed by shovel or wheel loader and no haulage trucks are required.

A considerable number of mines around the world opt for a semi-mobile crushing plant. These plants are designed in such a manner that they can be relocated through the use of transport crawlers and/or multi-wheel trailers. Having the flexibility to relocate the crushing plant enables travel distances for haulage trucks and belt conveyors to be optimized during the life of the mine - all with a view to providing increased efficiency and flexibility to the mine operator. Choosing the optimal crushing plant location is an essential criteria for the reduction in the number of haulage trucks required and increase in operational efficiency.

For mines or quarries boasting mineral deposits with smaller extensions and/orwith short haul distances between bench and plant, a stationary crushing plant is usually the most optimal solution.Variations in production caneasily bematched by increasing or decreasing the number of haulage trucks.

Capital and operational costs of an operation depend directly on the material transport system. Conventional truck haulage as todays predominant means of material transport in surface mines are well established and provide excellent flexibility, however contribute up to 60% of the overall mining cost. Further to the potential operational expenditure (opex) reduction, IPCC systems also offer a number of other benefits to mining operations ranging from an increase in safety to reductions in dust, noise and greenhouse gas emissions, increased automation and bad weather downtime.

IPCC represents a viable, safer and less fossil fuel dependent alternative, comprising fully-mobile, semi-mobile or stationary crushing stations connected to conveyors and spreaders (for waste) or stackers (for ore) to transport material out of the mine.

superior mkiii 62-75 primary gyratory crusher - metso outotec

superior mkiii 62-75 primary gyratory crusher - metso outotec

Metso Outotec's product family of primary gyratory crushers is called Superior MKIII primary gyratory crushers. The MKIII stands for the third generation of the Superior primary gyratory crushers has developed during over 100 years in designing and manufacturing crushers.

The latest Superior MKIII primary gyratory crushers generation is again better, more efficient, safer, and simpler than the previous one. It was developed especially to meet the needs of customers facing ever-changing ore grades and conditions.

Intelligent measurement and analytics of crushing operations by control systems such as VisioRock and VisioTruck provide detailed reporting and online analysis of plant operations for mineral processing. These optional automation tools can be connected to Superior MKIII primary gyratory crushers with ease.

Resistant U-shaped arched spider, durable manganese bronze spider bushing, new shell separators and inspection ports, as well as hardy one-piece main shaft makes Superior MKIII primary gyratory crushers efficient and lasting, but easy to maintain when needed.

All new Superior MKIII primary gyratory crushers features are retrofittable on existing Superior MKI and MKII primary gyratory crushers. This means that any equipment upgrades to existing Superior primary gyratory crushers can be implemented without issues.

primary crushing stations | primary plants | lippmann-milwaukee

primary crushing stations | primary plants | lippmann-milwaukee

Lippmanns range of large model jaws includes a 5062, 4248, and 3650 to suit your particular heavy duty, high volume primary crushing application. Compare a Lippmann jaw with any other jaw on the market. Immediately youll see the shaft and other components are larger, the frame much heavier. Everything about it tells you this machine was built for demanding production, strength and a lifetime of dependability. By incorporating these massive crushers into a stationary rockbox structure, Lippmann has perfected the first step in crushing applications

For years, the mining industry has relied on proven tractor- type apron feeders to handle rock during wet, sticky or frozen operations, and today Lippmann has perfectly configured the optimal primary plant for aggregate producers.

An inclined dump mechanism uses both gravity and hydraulics to remove oversized material from the crushing circuit. This unit comes equipped with tapered grizzly bars and can be operated by pendant or remote

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