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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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.
Choosing the appropriate stone crusher is important for every operation, but how to choose a right stone crusher? There are several characteristics to consider:
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.
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.
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.
The incoming and outgoing particle size is used to judge the model and crushing level of the required crushing equipment.
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.
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.
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:
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.
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.
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.
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.
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.
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.
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.
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Disadvantages: low production efficiency, unable to crush hard materials.
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.
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:
The stone crushing method 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: This combines both compression and shearing forces to fracture the material.
Impact crushing: Impact crushing involves high-speed movement of the crusher or material that strikes the material to be crushed. It includes:
This article introduces the key points of selecting a suitable stone crusher, multi-stage crushing and crushing methods. A multi-stage crushing process may be necessary, depending on the material's hardness and the desired output. By considering the crushing method, you can choose the equipment that best suits your operational requirements and performance goals.
We hope this guide helps you make a more informed decision when selecting your stone crusher!
Rock cracking powder is also known as expansive mortar, and buyers ought to learn about all its types, especially if they plan to buy large quantities. This powder is a non-explosive concrete demolition agent that expands upon mixing with water. As it expands, it exerts pressure on the surrounding rock, which leads to cracking and breaking of such rocks. It is mostly used in mining, excavating, and quarrying. Below are the common types that buyers are likely to encounter.
This powder contains compounds like calcium hydroxide, silica, and aluminum. When mixed with water, it generates controlled expansion pressure that fractures rocks slowly, steadily, and safely.
This type relies on the use of water and especially high-pressure water jets to crack the rocks. The hydraulic powder is especially useful in places where traditional explosives cannot be used due to environmental and safety concerns.
As the name suggests, this type uses resins and is ideal for large-scale commercial and industrial projects. This type tends to be strong and durable and can withstand a lot of pressure over time.
These formulations are becoming increasingly popular due to rising environmental concerns. This was particularly so for quarries and mining companies that have to comply with regulations on environmental protection. These types include non-toxic rock cracking powder, which are mostly based on natural mineral compounds. There are also biodegradable rock cracking powders that have been developed to reduce the impact of drilling on the environment. These Include calcium carbonates or montmorillonite clay that are kind to the environment.
Rock cracking powder continues to gain more and more applications across different industries. They are particularly preferred to explosives since they are much safer, easier to use, and more effective. Here are some of the most common industrial applications where this powder is used.
Rock cracking powder is used to extract minerals and elemental matter from the mines. For instance, it could be crack concrete powder which is used to break down hard rock formations. This makes it easier to mine materials like coal, gold, copper, lithium, and even rare earth elements. Its ability to create controlled fractures makes it valuable for the mining industry, which has to minimize the risk of accidents in the mine.
Quarrying operations use rock cracking powder to extract stone materials. Usually, quarry owners employ this powder to produce aggregates for construction, which is less expensive and safer than using explosives. The powder is used to create steady expansion in the rocks to produce large, manageable sizes of quarry stones and gravel without generating shock waves.
The tunneling and excavation industries use a lot of rock crack powder. The powder is used during the construction of tunnels for roads, railways, and underground facilities. It helps create controlled cracks on the rocks, making it easier to excavate without collapsing the tunnels.
Rock cracking powder is also used in the construction of dams and reservoirs. Engineers use the powder to create controlled fractures in bedrock, which makes it easier to excavate the foundation for these massive structures. This minimizes the need for explosive charges while still ensuring the efficient removal of large rock masses.
Rock cracking powder can also be used in conservation projects to excavate around or remove sections of historic structures. The powder creates controlled fissures that minimize vibrations. It also minimizes the shock to sensitive materials in historical buildings and reduces the risk of damage to nearby structures.
Rock cracking powder is widely used for controlled demolition in areas where blasting cannot be used. For instance, the powder can be used to dismantle bridges, buildings, and other structures. It reduces noise, vibration, and fly rock. This allows easy demolition of concrete and masonry in densely populated areas.
Rock cracking powder has some unique features that set it apart from other alternatives like explosives. Although there are several types of rock cracking powders, almost all of them have similar features. Here are some of the main features that buyers need to keep in mind when purchasing this product.
This is perhaps the most important feature of rock cracking powder that makes it preferred to explosive. When applied correctly, it is much safer than using explosives. There are no safety issues arising from handling explosives. Additionally, rock cracking powder still produces fewer flying rocks and debris. There are also no shock waves or vibrations that could endanger the workers or the equipment in the mining area.
This is another key feature that makes rock cracking powder so effective. Most rock crack powders are designed to expand slowly and steadily. This results in controlled and even cracking of the rock. This makes it easier to manage and predict the outcomes compared to explosives.
Rock cracking powder can be used across various industries ranging from mining and quarrying to construction, tunneling, and even controlled demolition. Buyers can also use it to break different types of rock, concrete, and masonry. This makes it such a versatile product.
Using rock cracking powder is often cheaper than using explosives or other mechanical methods. This is because it requires fewer permits and less labor to apply. Also, since the cracking is more controlled, less material is wasted and there is less chance of damage to surrounding areas.
Most rock cracking powders have been designed to cause minimal environmental impact. Most of them are made using non-toxic and eco-friendly materials. This helps reduce dust, noise, and vibration during mining or quarrying. As earlier mentioned, this makes them ideal for use in sensitive areas or projects that have strict environmental regulations.
This powder has several types, each suited to a certain application. The expansion pressure, grain size, and setting time vary with each type. Here are some important considerations buyers should make when purchasing this powder in bulk. They not only affect the effectiveness of the powder but also the satisfaction of the end users.
The type of rock on which the powder will be applied determines the type of rock cracking powder to buy. Softer rocks like limestone and sandstone require less expansive powders. On the other hand, harder rocks like granite and basalt need highly expansive powders with controlled expansion to create sufficient cracks.
The environmental conditions in the mining area also determine the kind of rock cracking powder to buy. If the working conditions are too wet or too dry, choose a powder that is resistant to these conditions or has been formulated for such a scenario. Also, consider the temperature. It could be either too high or extremely low. These factors could affect the composition of the powder and the time it takes for the cracks to form on the rock.
The size of the project from which a buyer is purchasing this powder also matters. For small projects, a buyer can use a small rock cracking powder quantity, which is also easy to mix and apply. Large projects need large quantities of rock cracking powder that can be easily mixed and applied. They should also have a high yield to avoid incurring additional costs on cracking the rocks.
Different projects have different regulations, especially concerning vibrations, noise, and dust. These factors are critical since they can end up affecting the surrounding communities. Therefore, when buying rock crack powder, consider the compliance requirements. Ensure the powder meets all the required environmental standards to avoid conflicts and project delays.
The ease of mixing and applying rock cracking powder varies with its type. Some types require complicated mixing and have short or long setting times. Consequently, they become hard to control. For large projects or those where the workers have little experience, purchase a powder that is easy to mix with simple application techniques and a manageable setting time.
Most rock cracking powders contain non-toxic mineral-based compounds. Therefore, they are safe for plants as well as surrounding vegetation. They have been specially formulated to minimize their impact on the environment. To further prevent plants from being harmed, buyers should purchase rock cracking powder for sale that contains biodegradable components.
The average time required for rock cracking powder to expand is between 24 and 48 hours. However, this depends on several factors like the type of powder used, environmental conditions, and the rock composition. For instance, the setting time of rock cracking powder is shorter in wet conditions and warmer temperatures. It could be longer when the temperatures are low.
No, once rock cracking powder has been mixed with water, it cannot be regrounded and reused. This is because mixing water activates the chemical reaction that leads to expansion. Regrinding the mixture will not return it to its original state. Buyers should therefore purchase only the amount of rock fracture powder they need to avoid wastage.
Although most rock cracking powders are effective on both horizontal and vertical surfaces, some are better suited for specific applications. Some types are designed to adhere more effectively to vertical surfaces. This prevents the mixture from sliding off during application. Buyers should consider the type of surface on which the powder will be applied before purchasing it.
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