Zhongxiang: Your Premier Crusher Manufacturer
Professional Team
The company has a standardized factory building of 5,000 square meters, more than 90 workshop workers, 15 sales teams, 12 technical teams, and 8 after-sales service teams.
Perfect Management System
We have a complete factory production, quality supervision system, delivery process and after-sales service system to provide all customers with high-quality products and professional services.
Wide Range of Applications
Our products cover crushers, charcoal machines, wood processing series, etc., which are widely used in mining, metallurgy, building materials, bridges, refractory materials, highways, agriculture, forestry and other industries.
Complete Qualifications
With its strong technical strength and sophisticated processing equipment, the company has passed ISO9001:2008 international quality system certification, as well as PVOC, CE, SGS and other certifications.
Product Categories
A crusher is a machine designed to reduce large rocks into smaller rocks, gravel, sand or rock dust. They are often utilized in aggregates production, construction material recycling and in mining operations. 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 rock ore), so that pieces of different composition can be differentiated.
Benefits Of Using Rock Crushing Equipment
Improved Versatility
Rock crushers can be used for a variety of applications, making them versatile tools that can be effective for multiple types of uses.
Increased Efficiency and Productivity
When you use a rock crusher, you can crush large rocks into smaller pieces quickly and easily. This allows you to get more work done in less time, increasing your overall efficiency. In addition, if you choose the proper equipment, you will be able to complete the aggregate production process much more quickly and cost-efficiently.
Reduced Labor Costs
With the proper rock crusher for your project’s needs, you can get projects done with more speed. Be sure to understand the unique needs of your project and obtain the machinery that is best suited for the job to keep labor costs down.
Improved Product Quality
By crushing rocks into smaller pieces, you create a more uniform product that meets your exact specifications. This improves the quality of your product and helps you stand out from the competition. Certain types of rock crushers are better at handling this type of task than others.
Increased Production Capacity
The production capacity of your business will increase when you use rock-crushing equipment. This is because the equipment will enable you to handle more rock volume quickly, which means that you can produce more in a shorter amount of time.
Functions of Crusher
Reduction of Size
Crushers reduce the size of larger solid materials into smaller pieces, making it easier to handle.
Breaking Down Materials
Crushers are used to break down materials such as rocks, ore, concrete, and other materials into smaller pieces that can be processed or disposed of.
Separation of Materials
Crushers can be used to separate different types of materials from each other, such as separating iron from iron ore.
Recycling
Crushers are used to recycle waste and unused materials, reducing the amount of waste that goes to landfills.
Four Basic Ways to Reduce Material Size
Impact
Instant collisions of large objects against one another with material placed between. Both objects can be in motion or one can be still while the other strikes against it. There are two main types of impact reduction, gravity and dynamic.
Attrition
Rubbing the material between two solid surfaces. This is an appropriate method when reducing less abrasive materials because it consumes less power during the process. Robust materials would not be as efficient.
Shear
Typically combined with other reduction methods, shearing uses a trimming method and is used when a coarse outcome is wanted. This reduction method is often seen in primary crushing.
Compression
A key mechanical element of jaw crushers, compression reduces materials between two surfaces. Great for very hard, abrasive materials that do not fit attrition crushers. Compression is unsuitable for anything tacky or gummy.
Types of Crushers
Primary Crushing Equipment
Gyratory Crushers:
Gyratories are compression crushers primarily used for heavy mining and quarried materials in extremely high tonnage applications. They are ideal for dry to slightly wet material but not sticky material. The main features of a gyratory crusher include a tall crushing chamber lined with replaceable manganese wear plates, a main shaft with head and mantle, and a spider to anchor the top of the main shaft bearing.
Feeder-Breakers:
Feeder-Breakers, which combine both feeding and crushing into one machine, are used for the primary crushing of friable materials that can be slightly abrasive, dry or wet, but not sticky. They are typically used in heavy mining applications to provide the primary crushing and to make a beltable product to be conveyed for further downstream processing.
Jaw Crushers:
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.
Sizer Crushers:
Sizer crushers are used for the primary crushing of soft to medium hard material that can be slightly abrasive, dry, or wet and sticky. They are best suited for heavy mining applications and provide a typical reduction ratio of 4:1. These types of crushers offer a low profile and high throughput capacities with low roll speeds.
Secondary Crushing Equipment
Impact Crushers:
Impact crushers involve the use of impact rather than pressure to crush material. The material is contained within a cage, with openings on the bottom, end, or side of the desired size to allow pulverized material to escape. There are two types of impact crushers: horizontal shaft impactor and vertical shaft impactor.
Hammermills:
Hammermills can be used in many types of aggregate and industrial applications, including limestone, marble, shale, gypsum, phosphate, bauxite, aluminum dross, uranium, cryolite, clinkers, quicklime, petroleum coke, coal and more.
Roll Crushers:
Roll Crushers are compression-type machines, so output gradation is controlled mainly through the gap setting between the rolls. A wider setting results in a coarser product. A wider setting also provides greater throughput. Roll Crushers are available in several designs.
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. 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. There are also impact-style rock crushers—namely HSI and VSI equipment.
Tertiary Crushing Equipment
Screening Equipment:
If a piece of material is too large for the crushing machine to effectively handle, it must be removed. Screening equipment removes any material that will slow the production process. It sorts and classifies materials by size using a series of screens with different sized openings. These openings, or grids, allow small rocks to move along and large rocks to be excluded.
Conveyors:
There are two basic kinds of conveyors, powered and gravity. Powered conveyors utilize energy from an outside source whereas gravity conveyors use the material’s weight to propel them.
Comparison of Different Crushers
|
Crushers |
Pros |
Cons |
|
Jaw Crushers |
It has a simple structure. Manufacturing cost is low. It is easy to configure. Convenient inspection, repairs, and maintenance. It is a reliable crusher. |
It consumes a lot of power. Less productivity. Its products are in uneven sizes. It has a small crushing ratio. High vibration. |
|
Impact Crushers |
It has a simple structure. A higher crushing ratio. Convenient equipment operation and maintenance. High productivity. |
The operation unit is noisy. It is unable to produce particles with completely even sizes. |
|
Hammer Crushers |
High productivity. A higher crushing ratio. Low power consumption. It has a simple structure. Its products are even sizes. |
Materials may clog equipment screens. It causes excessive wear due to fine grinding of hard and abrasive material. It takes longer to examine and repair. |
|
Cone Crushers |
Sturdy construction High productivity Easy adjustment Low operational costs Inexpensive machine |
The cone crusher cannot take material of all sizes. The finished product is not homogeneous. Not suitable for handling clay or metal mixed with rock. |
How to Choose a Crusher?
The type of material you need to crush will help determine the type of crusher you will need. Some crushers are designed to handle softer materials, such as coal, while others are better suited for harder materials like granite.
Consider the amount of material you need to crush on a daily, weekly, or monthly basis. This will help you determine the size and capacity of the crusher you need.
The size reduction ratio is the ratio of the size of the material after crushing to the size of the material before crushing. A larger size reduction ratio means that the crusher can reduce the size of the material more effectively.
Crushers that are used for abrasive materials will wear out more quickly than those used for softer materials. Consider the wear resistance of the crusher when selecting one for your application.
Some crushers require more maintenance than others. Consider the amount of maintenance required for the crusher you are considering, as well as the availability of replacement parts.
The cost of the crusher should also be considered when selecting a type. Be sure to consider not only the upfront purchase price, but also the ongoing operating costs.
If you are crushing materials that are hazardous or have the potential to release harmful substances into the environment, be sure to select a crusher that is designed to minimize these risks.
Applications of Crushers
At a Demo Site
Crushers on a building demolition site compress and recycle materials like concrete, asphalt, and brick. These crushed materials can be reused as a base for new construction projects or as aggregate.
In a Quarry
These rock crushers break down huge rocks like limestone, granite, and sandstone. These materials can then be used for construction, road base, landscaping, and oil fracking.
On the Road
You’ve probably driven by dozens of rock crushers while trying to navigate your way through the middle of road construction projects. Material crushed on a road job is reused under or in the new road.
In the Mine
Mining rock crushers break down materials into smaller pieces for easier removal and downstream processing for taking out essential minerals and metals.
Sand and Gravel
This is one of the most unique of crushing applications. Round boulders are one of the hardest materials to crush because of compressive strength and also one of the more challenging materials due to the shape.
A Recycling Yard
These crushers help process materials, including concrete, asphalt, and demolition waste, that can be recycled into something new. This lessens the need for new products and reduces waste.
Components of a Jaw Crusher
The jaw crusher is one of the most admired and most sought after equipment from the house of Zhongxiang. For the benefit of newcomers in the industry, here is an explainer of the various components of the Jaw crusher.
- Crusher Body The design of the crushing body ensures that it is capable of exhibiting resistant to bending stress even when the crushing hard materials.
- Pitman The pitman usually denotes a connecting rod, but in a jaw crusher it does not connect two things. Here, it refers to the moving jaw in a jaw crusher. It achieves the reciprocating movement through the eccentric motion of the flywheel shaft. This creates enormous force in each stroke.
- Jaw Plate The inward facing side of the jaw crusher pitman is covered with a jaw plate made of manganese which is an extremely hard metal. The jaw plates are usually symmetrical from top to bottom and can be used on either side.
- Rear End Frame The fixed jaw face is opposite to the pitman face and is statically mounted. It is also covered with a manganese jaw plate. Manganese liners (Jaw plate) protects the frame from wear. These include the main jaw plates covering the frame opposite the moving jaw and the cheek plates which line the sides of the crusher body within the crushing chamber.
- Eccentric Shaft The pitman is put in motion by the oscillation of an eccentricity on a shaft that goes through the pitman's entire length. The eccentric shaft is made of Alloy Steel Fitted with anti-friction bearings and is in the pitman and dust proof housing.
- Flywheel The rotational energy is fed into the eccentric shaft of the jaw crusher by means of a sheave pulley which usually has multiple V-belt grooves.
- Jaw Crusher Bearings There are typically four bearings on the eccentric shaft: two on each side of the jaw frame supporting the shaft and two at each end of the pitman. These bearings are typically roller in style and usually have labyrinth seals and some are lubricated with an oil bath system.
- Toggle Plate The bottom of the pitman is supported by a curved piece of metal called the toggle plate. It allows the bottom of the pitman to move up and down with the motion of the eccentric shaft, apart from serving as a safety mechanism for the entire jaw.
- Retraction Spring & Screw Rod Without the spring & retraction screw rod, the bottom of the pitman would just flop around as it isn't connected to the toggle plate and is just resting against it in the toggle seat. The retraction screw rod system ensures the pitman is firmly fixed to the toggle plate.
- Cheek Plates The sides of the crusher body are covered with cheek plates. It is made of high-strength manganese steel plates and are wear resistant.
- Setting Adjustment Varying material output size (discharge) is achieved by adjusting the opening at the bottom of the jaw, commonly referred to as the "closed side setting". This can be done by inserting shim plates, wedge movement and hydraulic system.
What is the Process of Crushers?
Material Screening
After the crushing stages, the material may go through a screening process to separate finer particles and ensure a uniform size distribution.Screening helps in controlling the quality of the crushed material.
Storage
The crushed and screened material is then transported to storage silos or stockpiles.
Primary Crushing
The raw materials, such as limestone, shale, clay, and iron ore, are extracted from quarries and mines.The extracted materials are transported to the primary crusher, which is usually a jaw crusher.The jaw crusher breaks down the large rocks into smaller pieces.
Secondary Crushing
After primary crushing, the smaller pieces are conveyed to secondary crushers for further reduction in size.Common types of secondary crushers include cone crushers, impact crushers, and gyratory crushers.
Tertiary Crushing
Some plants may have a tertiary crushing stage to further reduce the size of the material.Tertiary crushers are used to produce finely crushed material that is suitable for the production of cement.
How to Install a Crusher?
Prepare the Site: Clear the area where the stone crusher will be installed and level the ground. Make sure there is adequate drainage and that the site is accessible for heavy equipment.
Lay the Foundation: Dig a trench for the foundation and pour concrete or compact the soil. Make sure the foundation is level and stable.
Assemble the Crusher: Follow the manufacturer's instructions to assemble the stone crusher. Make sure all bolts and nuts are tight and that the machine is properly aligned.
Connect the Power Source: Connect the stone crusher to a power source, such as a generator or electrical outlet. Make sure the machine is properly grounded.
Test the Crusher: Turn on the stone crusher and test it for proper operation. Make sure there are no leaks or other issues.
Maintain the Crusher: Regularly maintain the stone crusher by lubricating moving parts and checking for wear and tear. Follow the manufacturer's instructions for proper maintenance.
Operating a Stone Crusher
To operate a stone crusher, follow these steps:
Turn on the feeding machine and conveyor belt and make sure they are working properly.
Turn on the crusher and adjust the crushing size.
Feed the stones into the crusher.
Observe the crushing process and make any necessary adjustments.
Turn off the crusher and turn off the feeding machine and conveyor belt after the crushing is complete.
Best Practices for Crusher Maintenance
Jaw Crushers
- Check oil regularly, making sure it is free of dirt and contaminants.
- Check jaw dies every day, and make sure bolts are fastened securely.
- Maintain crusher backing to ensure proper vibration and impact protection.
- Keep breathers clean.
- Make sure the toggle area is clean, especially prior to any adjustments.
- Wash out seats and plates daily.
Gyratory Crushers
- Check spider bushing clearance monthly, every 500 hours, or with every mantle change. Whichever comes first.
- Monitor and maintain bushing lubrication levels every day (about 1.4" above bushing flange). Make sure "extreme pressure" additive is added.
- Check balance cylinder(s) every 30 days of operation.
- Keep oil and lubrication clean. Check daily, every 8 hours.
- Follow crusher backing maintenance schedule carefully to avoid undue damage to equipment.
- Every 40 hours, check for leaks and inspect Y strainers.
- Every month, inspect safety devices and perform an oil analysis.
- At least once per year (or every 2,000 hours) change all oil.
- Know and use the proper mantle for your crusher. Failing to do so can result in serious damage.
Cone Crushers
- Keep cone crushers choke fed during operation. This will prolong manganese service life and maintain quality shape of the product.
- Maintain oil cleanliness. Check daily.
- Lubricate bearings every 500 hours and change oil every 6,000 hours.
- Make sure crusher backing is applied regularly to protect parts, components, and to fill in gaps.
- Use the correct oil for manufacturer’s requirements and climate conditions.
- Check the main frame for damage. Use a micrometer for variance and quality control. Replace or machine areas that cannot be filed down with an emery cloth.
- Check alarms daily to make sure they are working properly.
Grinding Mill Crushers
- Keep your equipment clean, preferably cleaning after each use. From heads to cables and hoses to the remote control unit, keeping your grinder clean will give you optimal usage for the entire life of the machine.
- Check for uneven wear on tooling, cracks, or other damage. This may be an indication of a damaged tool holder.
- Use OEM parts only.
- Pay attention to strange sounds, scratch patterns, power loss, or anything else out of the ordinary.
- Perform a deep clean on your mill weekly, breaking down the tips, checking for wear and erratic oscillation, belt slippage, and proper battery maintenance if applicable.
- Every 100 hours do a full breakdown and inspection, being sure to clean the mill and make sure everything is in proper working order.
- A yearly tune-up from a professional service provider will give you the edge when it comes to keeping your machinery up and running well.
Tips for Crusher Safety
Ensure Proper Ventilation
Crushers can generate dust and debris, which can be harmful to workers’ health. Ensure that the work area is adequately ventilated to reduce the risk of respiratory issues.
Do Not Alter the Machine’s Settings
Changes to the machine’s settings can cause equipment failure, leading to accidents and injuries. It is essential to follow the manufacturer’s instructions for using the machine.
Shut Down When Not in Use
Shut down the crusher when it is not in use, especially during breaks and at the end of the workday. Turning off the machine will prevent it from accidentally starting up, which could lead to accidents and injuries.
Get Familiar With the Machinery
Before operating a crusher, it is essential to read and understand the instruction manual. Understanding the manual will help you to understand how to use the machine properly, including safety precautions, as well as the machine’s features and limitations.
Wear Personal Protective Equipment (PPE)
Wearing personal protective equipment (PPE) is essential when operating a crusher. The equipment should include safety glasses, gloves, and earplugs to protect your eyes, hands, and ears, respectively. A hard hat and steel-toed boots are also necessary for protection from falling debris.
Keep the Work Area Clear at All Times
It is important to keep the work area clear of debris, tools, and other equipment. Clearing the work area will help prevent accidents and keep workers safe from tripping or falling over objects. Ensure that there is adequate space around the machine for easy movement and access.
Inspect Machinery
It is crucial to inspect the crusher before use to ensure that all components are in good condition. Check for any cracks or damages that could affect the machine’s performance, and make sure that all safety guards are in place.
Never Overload Machinery
Overloading a crusher can lead to equipment failure, which can result in accidents and injuries. Always ensure that the machine’s capacity is not exceeded and do not attempt to crush materials that are too large or too heavy.
Keep Away From Moving Parts
It is essential to keep your hands and clothing away from the moving parts of the crusher. The machine’s moving parts can cause serious injuries, so always ensure that you keep a safe distance.
How to Effectively Improve the Production Capacity of the Crusher?
Optimize the Feed Size and Gradation: The feed size and gradation of the material can significantly affect the production capacity of the crusher. A larger feed size and a finer gradation can increase the capacity, but it may also increase the wear on the crusher. It is important to find the right balance between these factors.
Proper Maintenance: Proper maintenance of the crusher can help to increase its production capacity. This includes regularly inspecting and replacing worn parts, lubricating the crusher and keeping it clean.
Use the Correct Crusher Type: Different types of crushers are designed to handle different types and sizes of materials. Using the correct crusher type for the material being crushed can help to increase the production capacity.
Increase the Speed of the Crusher: Increasing the speed of the crusher can also increase the production capacity, but it may also increase the wear on the crusher and the risk of accidents. It is important to carefully consider this option and ensure that the crusher is operating within its design limits.
Upgrade the Crusher: If the production capacity of the current crusher is not sufficient, upgrading to a larger or more advanced crusher may be necessary. This may involve purchasing a new crusher or making modifications to the existing crusher.
We have a complete factory production, quality supervision and delivery.
Our Certificate
At present, the company has ISO9001:2008 international quality system certification, as well as PVOC, CE, SGS, and other certifications.
Ultimate FAQ Guide to Crusher
Q: What is crusher used for?
Q: What are the types of crushers?
Compound crusher
Horizontal shaft impactors
Vertical shaft impactors (shoe and anvil)
Q: What is a rock crusher called?
Q: What is the difference between grinder and crusher?
Q: What are the disadvantages of crusher?
Q: What is a crusher in construction?
Q: Which type of crusher is best?
Q: How do you crush rocks?
Q: What is crusher or medicine crusher?
Q: What is a crusher in heavy equipment?
Q: What is a rotary crusher?
Q: Is hammer mill a crusher?
Q: Is a ball mill a crusher?
Q: Is hammer mill a crusher or grinder?
Q: What is the lifespan of crusher?
Q: What are the problems with stone crushers?
Q: What type of crusher is best for concrete?
Q: How do I choose a crusher?
Q: Why use concrete crusher?
Q: What is the best crusher for sandstone?
Q: What is the principle of crusher?
As one of the leading crusher manufacturers in China, we warmly welcome you to buy high-grade crusher for sale here from our factory. All our products are with high quality and competitive price.
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