Are you a construction business owner or contractor looking to crush concrete, rock or asphalt? If so, you may be wondering what a crushing plant is. A crushing plant is a row of machines that break down large chunks of material into smaller pieces in the quickest most efficient way.
Crushing plants are an important part of the mining, quarrying, and recycling industries. They can even be set up as stationary plants or mobile ones, depending on your business's needs. In this blog post, we will find out the different kinds of crusher plants in more detail.
A crushing plant setup is a series of machines that are designed to take large pieces of concrete, asphalt or rock and break them into smaller pieces. The crushed material can then be used for construction, landscaping, and other purposes.
There are many different kinds of machines used in a crushing plant. At the beginning of the plant is the excavator. This scoops up large blocks of concrete, rock or asphalt from your stockpile and places them into the first crusher. There are typically two types of crusher machines used in a plant setup: a jaw crusher or an impact crusher. There are lots of different sized and shaped excavators and buckets available, so you will always be able to find one for your specific job. You can check out all the different types of excavators here.
Excavators feed the crusher with material at the start of the crushing plantA jaw crusher is great for breaking down very large pieces of rock into smaller more manageable sizes. These smaller chunks can then be fed into an impact crusher. These work by metal rotors smashing the material against the inside an impact chamber. Creating a much smaller material that is a similar shape and size. If you are thinking of running a jaw and impact crusher in the sequence you should read this blog on primary crushers this has all the information you need to know. And, if you want to know more about the differences between jaw and impact crushers, just click the link!
You can also run a crushing plant without an impact crusher, especially if your budget is tighter.
For an in-depth look at the various types of crushers and their stages, check out this comprehensive guideJaw crusher feeding into a screener
If you're setting up a crushing plant, a screener can be an essential piece of equipment. It can help you to get the most out of your crushers by sorting the materials they make into stockpiles of the same size. You can then use these directly on your projects for landscaping or to make pavement fill or sell them for a profit!
When choosing a screener for your crushing plant, it's important to select one that is durable and easy to maintain. You'll also want to think about the type of material you'll be working with and the product you want to make. With so many options on the market, it's important to work with a reputable supplier who can help you choose the right screener for your needs. Machinery Partner is always here to help you choose the best screener for your business with a full range of scalping screens and trommels available directly from the manufacturer. Find out more about trommel screens and how they work.
A screener in your crushing plant will help you make high spec materialsWhen deciding between mobile and stationary crushing plants, you should think about the pros and cons of each setup.
Mobile crushing plants are easily transportable, cost-effective, and can be moved around quickly to different work sites. Mobile crushing plants require regular maintenance and may use more fuel, plus they can&#;t process as many materials at once. On the other hand, stationary crushers are usually located in one spot, so there&#;s no need to move them from job site to job site. This does however mean that you will lose the flexibility of being able to move it when needed and you will need to have a permanent location where the crusher and or screener will stay.
The choice between a mobile or stationary crushing plant depends on your needs: mobile units are better for short-term projects that require frequent travel while stationary ones are recommended for more time-intensive jobs that remain in one spot.
Static jaw crushers are great if you have a permanent location to keep themWhen it comes to crushers, bigger is better. Having just a crusher for your business can be fine for gravel, cement, and concrete but when it comes to more complex crushing materials, such as minerals, ore and metals, the jaw crusher isn't always enough.
Setting up a crushing plant gives you the ability to process higher volumes of material in different sizes much faster than a jaw crusher alone would. If you're processing different kinds of materials or just need to process large amounts of material quickly, then setting up a crushing plant is essential. Find out how to start crushing your own concrete here.
A crushing plant gives you access to larger crushers and screens so that you can process more material in fewer passes. You'll also be able to keep production running longer with smaller machines because there's less wear on them when compared with just using one crusher over extended periods. There are different kinds of plant set up - here is an example of a stone crusher plant set up.
In short, if you need high-volume crushing capabilities and are looking to expand your business into more complex areas of crushing materials, then setting up a crusher plant is your best choice! All in all, setting up a full crushing plant offers greater flexibility, better efficiency and improved productivity rather than relying on a single crusher alone. For an in-depth examination of crushed concrete, including its benefits, drawbacks, and frequently asked questions, don't miss our detailed blog post: Crushed Concrete: The Pros, Cons, and FAQs.
Setting up a crushing plant involves careful consideration and selection of all its machines to make sure they match each. This is the only way you can make quality materials with minimal wear and tear on machinery.
You should always think about the tones per hour (tph) each machine can handle. If your jaw crusher works at 200 tph, you can&#;t match it with an screener than can only handle 50 tph!
When you are setting up a crushing plant you also need to think about the feed heights of the machine's hoppers compared to the conveyor height of the machine in front of it. Take a look at this setup below. This is a jaw crusher feeding a screener. See how the conveyor of the jaw crusher nicely feeds into the screener?
Getting a bit complicated? Don&#;t worry - Machinery Partner are here to help. We have decades of experience when it comes to crushing and screening and can help you with all kinds of crushing plant setups and advice. Get in touch with a Machinery Partner expert today!
Matching conveyor to hopper height is important when setting up a crushing plantNeed crushers, screeners or excavators for your crushing plant setup?
Machinery Partner has you covered! We have a large selection of heavy equipment for sale including impact crushers at competitive prices. Our team of experts can help you navigate the range to find the best machinery for your specific crushing plant and material need.
Whether you're crushing stone, asphalt, or metal waste and debris, Machinery Partner can help you put together a set of crushers, screeners and excavators that will get the job done right. So if you want to get your crusher plant up and running quickly and efficiently, Machinery Partner is here to help. Call a Machinery Partner expert today!
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Written by Toyah Warnock
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.
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).
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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.
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.
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.
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.
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).
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 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!
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