Selecting the appropriate crusher is essential for each process. It is much easier to choose the correct crusher by knowing the various stages of crushing. Every crusher type has distinct functions and is designed to achieve a specific end result.

Similar to the stage before every crushing stage will be expected to produce a specific output for the next phase. Aggregate producers who match the right shredder parts stage to the proper stage will be most effective and profit-oriented.

Crushing stages

Most aggregate producers are well aware of the various options for crushing equipment, and they know that it's possible to pick the right equipment only on specifications sheets and calculators of gradation. It is nevertheless important to consider the theoretical findings against the actual experience of the material, as well as the maintenance, economic and operational features of different options.

Material reduction generally takes place in stages. While there are single-crusher alternatives, the most well-known systems include at minimum two or more crushing stage.

Primary crushing. The main function of the primary crusher is, above all making it possible to transfer material onto conveyor belts. The primary crushing process in the majority of aggregate crushing facilities is accomplished by using jaw crushers. But it is possible that a gyratory primary crusher can also be utilized. If material is easily crushed and is not too abrasive, an impact crusher could be the ideal option.

The most crucial aspects of a primary crusher is capacity and the capability to handle raw material without blockages. Bigger primary crushers can be more expensive to purchase than smaller models. This is why the initial investment costs for primary crushers are considered against the cost of blasting raw materials into smaller dimensions.

Trucks transport material from one place to the next. The costs of fuel, tires, maintenance and the return on investment must be taken into account.

A pit-portable primary crusher can be a cost-effective solution in cases where the producer is crushing on the quarry's surface. Modern crushers usually benefit from a mobile primary crusher that can move with the quarry face.

Intermediate (secondary crushing). The goal of the intermediate crushing process is to create different coarser fragments or to prepare materials for crushing in the final stage. When the intermediate crusher is used to produce railway ballast, product quality is important.

Other cases have no conditions for quality, but the product has to be suited to fine crushing. The aim is to get the lowest price and maximum reduction.

Fine (tertiary) crushing. At this stage, the quality and quantity of fine materials are decided. Quality requirements can be stringent for the final product, particularly within the aggregate industry.

The majority of the time the functions of fine crushing and cubing are combined in one crushing stage. Practical experience and theoretical knowledge are required when selecting a crusher for secondary crushing. This is why manufacturers should make sure they call an experienced application specialist to make sure a device is well-engineered.

Crusher types

Jaw crushers

A jaw crusher is an example of a compression crusher. It reduces the amount of material by pressing the feed material between a moving piece steel and a stationary piece. The setting or distance between the two steel pieces determines the size of the discharge. The setting is tighter which leads to a smaller output size and a lower capacity for throughput.

Jaw crushers are compression crusher and produce the most coarse materials. This is because they crush rock with the natural lines of weakness. Jaw crushers are a fantastic primary crusher when used to prepare the rock for the subsequent processing stages.

Cone crushers and gyratory crushers

They can also crush steel between two pieces of steel. The output is controlled by the setting between the two pieces.

Although the chamber is round in form, the moving piece of steel is not meant to rotate. Instead the wedge is pushed around to create compression on one side of the chamber and discharge opening on the opposite side. Cone crushers can be utilized as secondary or tertiary crushers however, they must be equipped with the lowest proportion of fines.

Impact crushers

Impact crushers use velocity and mass to reduce feed material. The feed material is initially diminished when it is placed in shredder parts, which rotates with the blow bars or hammers of the rotor. The second breakage happens when the material is accelerated into the stationary aprons , or breaking plates.

If shape is crucial in determining the shape of a rock, impact crushers are frequently employed. Impact crushers crush rock along natural cleavage lines. This results in higher quality products and form.

Final thoughts

When choosing the crusher that will best meet your requirements, it's important to understand the requirements for each stage.

In the initial stage, look to get materials to a size that your conveyors and other processing machines can handle.

Certain operations require additional crushing during the secondary or tertiary stages. These stages allow for better control over the size and shape of the final product.

Finding out how best to match the type of crusher to the correct crushing stage will ensure crushing efficiency throughout your operation and overall financial success.