Everything You Need To Know To Find The Best mobile crushing station for sale

Summary&#;Stone crusher is an indispensable part of crushing, sand making, grinding and other processes. This article will tell you how to select the right crusher for your stone crusher business.

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What's a stone crusher?

A stone crusher is a type of pulverizer that uses mechanical energy to break blocks of stone, concrete, or other building materials into smaller blocks of a specific grain size.

From very hard stones to soft minerals, crushers can be used for a very wide range of materials&#;they can be utilized in a variety of applications in industries such as mining industry to reduce the size of ore blocks and facilitate their processing&#;crushed stones previously used as building materials and demolition, crushing the debris left after the demolition of buildings, roads, bridges, canals and various other structures.

How to choose a right stone crusher?

Choosing the appropriate stone crusher is important for every operation, but how to choose a right stone crusher? There are several characteristics to consider:

1. Type and Hardness of Materials

The type and hardness of materials are the first factors to be considered in the selection of crushing equipment. Different types of materials will have different hardness and structure, which will have the primary limit on the selection of stone crusher. Generally, the greater the hardness, the higher the crushing difficulty coefficient.

2. Material Specification

If the material size is large, jaw crusher can be selected as primary crushing; When the size of stone is small and needs to be composed of stone with certain gradation, combined crushing and screening equipment shall be selected.

3. Humidity of Materials

The water content of the material will also affect the selection of the stone crusher. When the water content is too large, the fine materials will agglomerate or stick to the coarse materials due to the increase of humidity, so as to increase the viscosity of the materials, reduce the ore discharge speed and reduce the productivity. When it is serious, it will even block the ore discharge outlet and affect the normal production.

4. Granulometric Requirement

The incoming and outgoing particle size is used to judge the model and crushing level of the required crushing equipment.

5. Output Requirements

The output requirement is an important index to determine the crushing equipment. The higher the output requirement, the larger the required crushing equipment specification, and the corresponding input and output will increase.

6. Construction Site

The specific situation of the construction site is the most direct factor affecting the selection of crusher equipment, such as the site size of the construction site, the specific placement position of crushing equipment, etc.

7 Types of Stone Crusher

Understanding the application scope, technical advantages, and limitations of each stone crusher design enables operators can implement the best crushing solutions to maximize productivity and meet production targets.

These are the main stone crushers on the market:

1. Jaw Crusher

The working mode of the jaw crusher is intermittent, and the rock material is crushed by squeezing the rock by the fixed jaw and the movable jaw. Some time ago, a friend left a message to consult the single pendulum jaw crusher. In fact, it is rarely used now, and the compound pendulum jaw crusher is mainly used.

Application: It is suitable for a wide range of materials, both soft and hard, especially the coarse and medium crushing of hard stones.

Advantages: simple structure, reliable work, lighter weight, cheap price, small size, low configuration height, large feed opening size, easy adjustment of the discharge opening opening, simple maintenance, and economical operating costs.

Disadvantages: The liner is easy to wear, and the content of needle flakes in the product is high, and feeding equipment is generally required.

2. Cone Crusher

The work of the cone crusher is continuous, using the eccentric movement of the moving cone to crush the stone. At the same time, due to the tangential movement of the moving cone and the fixed cone, the stone will also be subjected to shearing and grinding. Therefore, its working mechanism It is a combination of extrusion, shearing, and milling methods.

Application: Mainly used for medium or fine crushing of various stone materials. At the same time, according to its different structure (suspended shaft type and supporting shaft type), it can also be used for coarse stone crushing (suspended shaft type is used less).

Advantages: large crushing ratio, high efficiency, low energy consumption, less dust, uniform product size, stable operation, low failure rate, and not easy to be crushed.

Disadvantages: The structure and maintenance are more complicated, the body is high, and the price is expensive.

3. Impact Crusher

Impact crusher is a machine that uses impact energy to crush materials. Adjusting the gap between the counterattack frame and the rotor can achieve the purpose of changing the size and shape of the material discharged.

Application: Mainly used for medium crushing and fine crushing of stones below medium hardness, and the shape of the crushed stones is better.

Advantages: small size, simple structure, uniform product size, selective stone crushing, and high output.

Disadvantages: The blow hammer and the counterattack plate are particularly easy to wear, especially for crushing hard rocks, which are more severely worn and need to be replaced frequently; it is not suitable to crush plastic and viscous materials.

4. Mobile Crusher

Mobile crusher is a new type of equipment. It has been optimized and innovated in structural design, equipment configuration and combined application. The combination is more flexible, which greatly widens the application field of tire mobile crushing station and truly realizes the proximity treatment of materials.

Mobile crushers can be further subdivided into tire type mobile crushers and crawler type mobile crushers. Although they have certain differences in specific structure and operation performance, they both have the characteristics of convenience, flexibility, walking and stopping and local operation:

1. Integrated design of the whole machine. The structure is compact, integrating crushing, sand making, screening and transportation, and the carrying equipment is flexible and diverse.

2. Additional power traction and drive. The locomotive traction or diesel power shall be used for walking, and the operation site shall be transferred at any time according to the demand.

3. Wireless remote control operation. Compared with the traditional fixed crusher, one person can operate it remotely, which saves manpower and worry.

Understanding the crushing stage and the type of crusher best suited for each stage can simplify equipment selection. According to our practical application, the most suitable stone crusher is selected for our quarrying operations.

5. Sand Making Machine

The work of the impact sand making machine is continuous. It uses high-speed moving materials to strike iron, strike each other and friction between the materials to break. There are two crushing methods: "stone-on-rock" and "stone-on-iron".

Application: "Stone-on-Stone" is suitable for abrasive materials with medium-hardness and above. The finished product has a better grain shape and a little more powder content; "Stone-on-Iron" is suitable for materials with low abrasiveness and lower than medium-hardness, with high crushing efficiency. The wear cost of the guard plate is higher, and the finished grain is slightly worse.

Advantages: low energy consumption, high output, large crushing ratio, small size of the equipment, easy operation, convenient installation and maintenance, with shaping function, cubic product, high bulk density, and the machine's counterattack plate wears very much during operation Less.

Disadvantages: The maintenance is complicated and the cost is high. Generally, the maximum feed size does not exceed 60mm, which is suitable for fine crushing and sand making.

6. Hammer Crusher

The hammer crusher operates on a continuous crushing principle. As the high-speed rotor spins, the attached hammer heads deliver repeated blows to the feed material, effectively breaking down the stones and rocks.

Application: it is suitable for medium and fine crushing of medium and low hardness and non abrasive stones (compressive strength less than 100MPa). It can also be used for sand making when there are grate bars, but it has been rarely used.

Advantages: large crushing ratio, high output and more fine materials.

Disadvantages: the hammer head wears fast, needs to be replaced frequently, raises dust during work, and viscous materials with raw material moisture content greater than 12% cannot pass through effectively.

7. Roller Crusher

The work of the roller crusher is continuous. The stone is located between two parallel cylindrical rollers that move toward each other. The friction force between the stone and the roller bites the stone into the roller, facing the stone of the smooth roller. After being squeezed, the stones on the toothed roller are split and squeezed and broken.

Application: Mainly used for medium crushing and fine crushing of medium hardness stones (compressive strength below 100MPa) such as coal and limestone. Roll crusher is not used in road gravel processing.

Advantages: simple, compact structure, low investment, convenient adjustment, and can be used to crush viscous materials.

Disadvantages: low production efficiency, unable to crush hard materials.

What Is Primary, Secondary, and Tertiary Crushing?

If you want to buy a suitable rock crusher, you also need to know the multi-stage crushing stages is in a complete crushing production line. Stone crushers are classified according to the fineness with which they fragment the starting material. There are primary crushing, secondary (intermediate) crushing and tertiary crushing. Some production lines may include a single crushing stages&#;the most common production lines involve at least two or three crushing stages.

1. Primary Crushing

As the first stage during a crushing circuit following extraction from a mine site, primary crushing reduces material to a size and shape which will be handled by the secondary crusher. The duty of the first crusher is to form it possible to move material on a conveyer belt . In most aggregate crushing plants, primary crushing is administered during a jaw crusher, although a gyratory crusher could also be used. If material is definitely crushed and not excessively abrasive, an impression crusher could even be the simplest choice as a primary crusher.

2. Secondary (Intermediate) Crushing

In secondary crushing, reduction ratios become an important consideration. Knowing just how fine you would like your final output to be, along side the feed requirements of your tertiary or final reduction crushing station, will assist you determine what proportion reduction must happen within this stage.

Cone crushers are often placed within the secondary crushing station because they're versatile in terms of feed, closed side setting, speed, and throw. With cone crushers, though, it's essential to work them at consistent choked settings to stay productivity up.

3. Tertiary Crushing

In this crushing stage, the standard and quantity of fine products are determined. Quality requirements are often stringent for the ultimate products, especially within the mixture industry. Customer requirements common to both the mixture and mining industries are capacities and quality (fraction/particle size). the mixture industry has additional quality demands like soundness and particle shape (cubicity).

what is the crushing method?

Rock stone crusher is an indispensable part of crushing, sand making, grinding and other processes. However, there are many types of stone crushers on the market. How to choose suitable and satisfactory products?

Understanding the crushing method is very helpful for you to choose the right stone crusher. The crushing method refers to how rock particles are fractured during the crushing process. It is an important factor to consider when selecting the appropriate type of stone crusher.

Before understanding the stone crusher, it is necessary for us to have a simple understanding of the crushing method:

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The crushing method of the crusher is divided into compression, splitting, breaking, shearing, impact or blow, etc. Generally, multiple action modes are mixed, and there is no single action mode.

Compression crushing: The working face of the crushing machine exerts pressure on the material sandwiched between it, and the material is crushed when the compressive stress on the material reaches the limit of its compressive strength.

Splitting and shearing crushing: The edges of the crushing working surface are wedged into the material to generate tensile stress inside. When the value exceeds the tensile strength limit of the material, the material splits and locally produces powder at the point of contact between the sharp edge and the material.

Bending and breaking crushing: The materials clamped between the working surfaces, such as simply supported beams or multi-supported beams subjected to concentrated forces, are mainly subjected to bending stress, but are subject to splitting at the contact point of the working surface.

Compression and shearing: a combination of squeezing and shearing.

Impact crushing: Impact crushing includes the impact of the high-speed moving crusher on the material to be crushed, the impact of the high-speed moving material on the fixed wall, and the mutual impact of the moving materials.

This article introduces the key points of selecting a suitable stone crusher, multi-stage crushing and crushing methods, hoping to help you find the most suitable equipment!

Do you need to process sand, gravel, minerals, rock, or other aggregate products and have not yet purchased or leased crushing equipment? There&#;s no question&#;you need to work with a capable and professional material handling equipment design and engineering company dedicated to selling, renting, and installing the best new crushers for your needs.

After all, our most recent Kemper Equipment success story illustrates what happens when an aggregate producer implements the wrong system design and material handling equipment!

However, if you&#;re new to the aggregate processing industry, you probably have a lot of questions about rock crushers. As foundational material handling equipment in all plants, crushers need to coordinate seamlessly with screens, conveyor systems, and washing equipment.

Today we&#;re breaking down everything you need to know about crushers to help you understand the questions you should ask as you search for the right material handling equipment for your operations.

Stages of Rock Crushing: Crushing Stations

It is common to use multiple crusher types within a project and set them up as stations in a circuit format to perform the necessary material reduction work. In many cases, primary, secondary, and tertiary, and quaternary stations are installed to reduce the rock to the desired size, shape, and consistency.

Of course, not all projects require all the stations or stages. Sometimes, primary crushing alone may offer enough reduction for your needs.

For instance, if the final size of your product only needs to be between 4 inches and 6 inches, a primary jaw or impact crusher can accomplish your goals. However, you will likely require a much finer product, and that means incorporating up to three&#;or even four&#;stations with a variety of crusher types.

1. Primary Crushing

As the first stage in a crushing circuit following extraction from a mine site, (or in the case of recycled asphalt production, delivery to the RAP processing plant via truck transport), primary crushing reduces material to a size and shape that can be handled by the secondary crusher.

Typically, the minimum setting on most primary crushers will be about 4 to 6 inches, as noted above. Compression-style jaw, cone, impact crushers, and gyratory crushers are most often appropriate as primary crushing equipment types, though there can be overlap between primary and secondary crushers as far as suitable types.

2. Secondary Crushing

In secondary crushing, reduction ratios become an essential consideration. Knowing just how fine you need your final output to be, along with the feed requirements of your tertiary or final reduction crushing station, will help you determine how much reduction needs to take place within this stage.

Cone crushers are often placed within the secondary crushing station because they are versatile in terms of feed, closed side setting, speed, and throw. With cone crushers, though, it is essential to operate them at consistent choked settings  to keep productivity up.

3. Tertiary/Quaternary/Final Reduction Crushing

The goal of the tertiary (third), quaternary (fourth) or final reduction stage of the crushing process is to size and shape rock or other material into a marketable product. Again, there may be overlap between stages in terms of which crusher styles work best.

Cone crushers, vertical shaft impactors (VSIs), horizontal impact crushers, or even high-pressure grinding roll crushers may be used in the final reduction position.

Types of Rock Determine the Crushers You Need

Sandstone, limestone, gravel, and granite are arguably the most common aggregates used in the construction industry today, but these rocks have very different hardness and abrasiveness characteristics.

The type of rock you plan to focus on processing in your operation will dictate the types of rock crushers you&#;ll need to include in your crushing circuit.

The more you know about the type of rock you wish to crush and what its end-use will be, the easier it is to choose the best equipment to achieve your project goals.

So, How Many Types of Rock Crushers Are There?

The question &#;how many types of rock crushers are there?&#; can be answered in a variety of ways depending on what the person asking is trying to learn about rock, sand, gravel, or mineral processing.

The answer might be three to four if you&#;re talking about setting up stations in a complete rock crushing plant. Those are the primary, secondary, and tertiary/quaternary/final reduction rock crushers, which we covered above.

Of course, there are also different styles of rock crushers. Compression-style jaw and cone crushers, for example, fit into the various stations in a crushing circuit (depending on factors like the sizes, varieties, and hardness of the rock you need to crush, as well as the necessary output).

The number of crusher types in terms of style and configuration can be more challenging to quantify, as there are lots of ways to customize rock crushers. However, you&#;ll find four basic designs&#;cone, jaw, gyratory, and impact crushers&#;operating within many crushing plants.

Jaw Crushers

In compression crushing, jaw crushers tend to be more of a blunt instrument compared to cone crushers, which is why they&#;re often used in the primary rock crushing circuit stage.

Jaw crushers are also known as &#;rock breakers&#; and are used to break up larger, harder materials into more manageable pieces. They tend to do well with many different types of materials and don&#;t display as much wear and tear as impact-style rock crushers. They also produce minimal fine materials and dust, though the finished product with this type of rock crusher almost always requires secondary crushing.

To learn more about jaw crushers, you&#;ll want to catch our previous blog post all about these tough pieces of material handling equipment and the most common questions operators have about jaw crushers.

Gyratory Crushers

Gyratory crushers feature a conical head and concave surface (often lined with manganese steel) and break apart material by compression through what is known as eccentric movement.

Like jaw crushers, gyratory crushers are often utilized in primary crushing stations, though they may sometimes be used as secondary crushers, as well.

Cone Crushers

Similar to jaw and gyratory crushers, cone crushers work by compression, which means they reduce materials by squeezing them until they break apart.

There are also impact-style rock crushers&#;namely HSI and VSI equipment (more on those in a moment).

Cone crushers are built with a rotating mantle in a concave bowl lined with manganese&#;this is similar to gyratory crushers, but the crushing chamber in cone crushers is not as steeply angled.

Cone crushers can accept medium-hard to very hard and abrasive feeds that might be dry or wet, though not sticky (whereas gyratory crushers are better at handling softer, dryer feeds). Their output will be a relatively cubical product, with a reduction ratio of about 6-to-1 through 4-to-1.

Understanding the operating principle of cone crushing equipment is best illustrated in a visual format&#;check out this demonstration video from our Kemper Equipment YouTube channel.

Impact Crushers &#; VSIs and HSIs

Impact-style crushers include VSIs, as well as horizontal shaft impactors (HSIs), and are best used with less abrasive rock types, like limestone. These types of machines break apart material by the impacting forces of certain wear parts known as blow bars and impact plates or toggles.

Some operations also use impact-style crushers after they have already used a different type of rock crusher that produces a more elongated stone. This helps further shape the crushed material into a finer consistency with a more cubical nature.

Impact crushers tend to be less expensive than compression crushers (aka cone and jaw crushers, which we already covered) and have a higher reduction ratio. They can also break sedimentary deposit-type rocks&#;limestone and similar&#;along natural lines, which rounds off sharp angles and weak edges. This can produce a result that is more sand-like in nature.

Drawbacks of impact crushers include their tendency to produce an excess of fine materials if used with softer rocks. Impact rock crushers can also require frequent part changes and can create a large amount of dust that can be an issue on some worksites.

Portable vs. Stationary Crushing Plants

Depending on the length of your project and how mobile your crushing equipment needs to be, you can choose either stationary or portable/modular crushing plants.

Stationary plants have long been preferred because they feature a higher capacity and efficiency and lower production costs with easier maintenance. They also have historically featured a lower energy cost if you have on-site electricity, and no additional equipment is needed to move them from place to place.

The tides are beginning to change, though, and portable equipment has been technologically advancing to the point that it may be able to replace stationary plants in the future.

It&#;s true that portable material handling equipment already offers unmatched production flexibility. For instance, if you need to move your crushing plant more than once a year to multiple job sites, you are likely better off investing in portable equipment.

These self-contained plants are better suited to smaller projects and can be moved from project to project as necessary. They are often still not quite as efficient and have less capacity than stationary plants, but they can be more cost-effective in the long run if you have multiple projects in different areas.

Kemper Equipment Has the Crushers You Need for Your Operation

Still have questions about crushers or any other aspects of aggregate processing and material handling?

Here at Kemper Equipment, we offer the best performing crushing equipment that will work hard to make any finished products you plan to produce&#;including sand, gravel, fertilizer, specialty mineral products, recycled asphalt, salt, coal, and slag&#;efficiently and affordably. Contact us today to discover how we can provide a custom-designed crushing circuit or retrofit a new rock crusher into your existing operation.

Are you interested in learning more about Hydraulic Cone Crusher for Sale? Contact us today to secure an expert consultation!