All roads, you might say, lead to the Vertical Shaft Impactor (VSI) because these crushers make it possible to create roadways and just about everything else. Francis E. Agnew of California patented one of the first Vertical Shaft Impactors in . His configuration stacked three VSIs atop each other to produce sand, thus starting the VSI evolution.
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Today, VSI crushers ' and the folks who rely on them ' have produced many configurations to include everything from the addition of cascading material into the crushing chamber, to air swept separation of lighter product. One version suspends the shaft from above like a sugar centrifuge. It's also one of the most feature-patented crushers, so some of the things mentioned here might be unique to a single manufacturer. VSIs apply a large amount of energy to crush material and that's why it's one of the most versatile crusher configurations today.
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When it comes to producing materials such as aggregate for road making, VSI crushers use a high-speed rotor and anvils for impact crushing rather than compression force for the energy needed for size reduction. In a VSI, material is accelerated by centrifugal force by a rotor against the outer anvil ring, it then fractures and breaks along natural faults throughout the rock or minerals. The product is generally of a consistent cubical shape, making it excellent for modern Superpave highway asphalt applications. The rotor speed (feet per minute) controls final particle size.
The VSI's high cubical fracture percentage maximizes first-pass product yield and produces tighter particle size distribution. It has a high-throughput capacity ideal for beneficiation (elimination of soft material). Properly configured the VSI accepts highly abrasive materials. It has simple operation and maintenance. You can quickly change product size by changing rotor speed or cascade ratio. Some models have reversible wear parts to reduce downtime. The VSI typically has low operating costs even in high-moisture applications because of reduced energy costs and low wear cost per ton.
There are some feed size limitations with a VSI because of the small feed area available in the center of the rotor. Tramp material in the feed such as gloves, tools, etc. can cause problems with imbalance. The high RPM and HP require careful balance maintenance such as replacing shoes on both sides of the rotor at the same time. High wear part cost may be a problem for some hard abrasive materials, but the VSI may still be the best option.
Major limestone applications are for Superpave asphalt aggregates, road base, gravel, sand and cement. Industrial uses include: corundum, corundite, ferro silicon, glass, refractories, silicon carbide, tungsten carbide and zeolite. Mining applications include: bauxite, burnt magnesite, iron ore, non-ferrous metal ore, perlite and trona sulfate. VSIs are excellent for everything from abrasive materials to waste and recycling applications.
The VSI is typically used after a primary or secondary crusher. This makes a VSI ideal for making sand and for making coarse and medium aggregates for concrete/asphalt production.
Feed size and characteristics will affect the application of a VSI. The feed size is limited by the opening in the center of the rotor. Normally less than 5-inch material is desired, but very large VSIs can handle up to 12-inch feed. Another feature that will affect application is moisture, which can make the feed sticky. Required production capacity is the final limiting criteria. Large primary horizontal shaft impactors can output up to TPH and more. TPH is about the maximum for a VSI because of the limiting motor size and the rising G-force of a high-speed rotor, which is calculated by multiplying the radius times the square of the RPM.
Shoe configurations are many: rock on rock, groups of rollers, special tip wear parts and many others. The metallurgy of the shoes is also highly varied. Rotors can have three to six shoes. The number of shoes is typically governed by the diameter of the rotor. The larger the diameter rotor, the more openings are possible. Computational Fluid Dynamics (CFD) mathematical models are utilized to simulate the flow and collision forces to reveal solutions for lower wear cost, consistent final product, and higher energy efficiency.
The material to be crushed is fed into the center of an open or closed rotor. The rotor rotates at high rpm, accelerating the feed and throwing it with high energy into the crushing chamber. When the material hits the anvil ring assembly, it shatters, and then the cubical shaped product falls through the opening between the rotor and the anvil and down to the conveyor below.
The rotor speed (feet per minute) controls final particle size. Speeding up the rotor will produce more fines, slowing it down will produce fewer fines.
The VSI features multiple rotor/anvil configurations for various applications. From open or enclosed rotors to the tubular rotor, each machine is configured for their unique application. In many cases the rotor table, rotor assemblies, anvil ring or rock shelf are interchangeable, allowing maximum application flexibility.
The open top metal rotor is good for large feed or medium to very hard material, but it will work best for softer materials. It can handle medium abrasive, dry or wet, but not sticky materials. High reduction ratios are common, which are excellent for sand and gravel production in closed loop systems. Shoe shape can change the production size range. A straight shoe face design produces finer product, and a curved shoe face design produces coarser material.
The tubular rotor creates higher tip-speeds, which increases first pass yield with tighter particle size distribution and also reduces the recirculation loads. One unique feature is that the rotor rotation is reversible, allowing wear on both sides of the tube. Rotating the tube itself one-quarter turn also doubles the wear.
The enclosed top plate on a rotor primarily prevents material from escaping from the top of the rotor, which could happen with an overfed open top rotor.
(Above: Rock shelf when VSI at rest. In operation, the brown rock fills the chamber to the upper roof ring. Rock impacts rock in operation.)
Any time the material or rock is used as an impact wear surface the term autogenous is used. Putting a top on the rotor table and shoes allows autogenous use. During operation of the VSI, a bed of material can be designed to build up inside the rotor against each of the shoe wall segments. The bed, which is made up of material that has been fed to the rotor, extends to a wear tip. The bed protects the shoe wall segment from wear.
Concerning the rock shelf anvil, it forms a near vertical wall of material upon which the accelerated material impacts. 'Rock-on-rock' crushing reduces maintenance but can require up to 30 percent of material recirculation before meeting size requirements. Also, the rock shelf anvil absorbs energy that could otherwise be used for breaking, which may reduce efficiency. More RPM may be needed to achieve the same result as a solid metal anvil.
Good for medium abrasive materials, rock-on-rock configurations of either or both rotor and anvil may produce consistent material with low-wear cost and can handle wet but not sticky conditions. Reduction ratios from 2:1 to 5:1 can be expected. It's widely used for quarried materials, such as sand and gravel.
Due to the many configurations of the VSI feed, rotor, anvil and open- or closed- system design; testing is the only way to ensure proper application of a VSI crusher.
The VSI is one of the most versatile crushers available on the market today. Even with some limitations, like feed size and output capacity, VSI features have been and continue to be developed to maximize first-pass yields and lower operating costs. If you test your process on full-scale equipment before choosing your VSI, you won't be disappointed.
Impact crushers are powerful machines that utilize impact force to reduce the size of materials.
They are commonly used in construction, demolition, and recycling applications to crush various materials such as concrete, asphalt, natural rock, and more.
At the core of recycling and construction industries, impact crushers play a pivotal role by breaking down materials such as concrete, asphalt, and natural rock into smaller, more manageable pieces. Their unique working mechanism utilizes the power of impact to reduce material size, making them a preferred choice for a wide range of crushing applications.
Impact crushing is versatile, serving various stages of size reduction, from primary crushing to the final step of the process. Material is fed into the crushing chamber, where high-speed hammers or blow bars attached to a spinning rotor break up the material. The impact of the hammers on the material breaks it apart, propelling it against impact plates or breaker blocks for further reduction. The process repeats until the material reaches the desired size and is discharged from the crusher.
Impact crushers are categorized based on the direction and position of the rotor. The two main types are:
' Horizontal Shaft Impactors (HSI)
Horizontal shaft impact crushers are known for their ability to process various feed materials, including highly abrasive ones. They are ideal for primary and secondary crushing, offering high reduction ratios and less fines production.
' Vertical Shaft Impactors (VSI)
VSIs excel in producing high-quality cubical aggregates. They are frequently used in tertiary crushing stages and recycling applications where material shaping is desired.
' Rotor: The heart of an impact crusher, the rotor generates the high-speed impact required to break down materials.
' Blow Bars/Hammers: Attached to the rotor, these components are the primary force behind material reduction.
' Impact Plates/Breaker Blocks: Serve to further reduce material size by redirecting and crushing it against solid surfaces.
' Aprons: Adjust the aprons when switching output materials or readjusting crusher settings due to wear progress.
' This technology can yield a reduction of 12-15 to 1, which is the greatest in the crusher category.
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' Impact crushers can process asphalt and softer materials that jaws and cones cannot.
' This type of crusher is high wear and requires blow bars to be replaced on a regular basis. The cost per ton is considerably higher to operate than other crushing methods.
' Impact crushers create considerably more dust than other technologies.
When comparing impact crushers, cone crushers, and jaw crushers, it's essential to understand their distinct functionalities to determine the right equipment for your specific application.
As mentioned, an Impact Crusher is excellent for processing materials like asphalt and concrete into smaller, uniform pieces, thanks to their high-speed impact force. They are particularly favored in recycling and demolition projects for their efficiency in reducing material size and producing fewer fines, which is crucial for the quality of the recycled output.
Cone Crushers are popular in a number of applications, including crushing hard and abrasive rocks, ores, and minerals. As commonly seen in mining, construction, and aggregate industries, cone crushers work by squeezing material between a rotating mantle and a stationary concave or bowl-shaped liner.
On the other hand, a Jaw Crusher is typically used for primary crushing, especially in mining and quarrying operations. They work by compressing material between a fixed and a moving jaw to break it into smaller pieces. Jaw crushers are known for their robust construction and can process hard, abrasive rocks and materials like granite (with the exception of small/mini jaw crushers which are not suited to hard rock).
The choice between these crushers ultimately depends on the project's requirements, including the material type, desired output size, and overall processing capacity.
Impact crushers are utilized across various industries for a multitude of purposes, including:
' Recycling Concrete and Asphalt
These crushers turn waste from demolition sites into reusable material for construction, significantly reducing the environmental impact and saving on disposal costs.
' Producing Aggregate for Construction
Impact crushers are critical in producing high-quality aggregates like gravel and sand, which are essential for modern construction projects.
' Mining Operations
Impact crushers efficiently process various minerals to reduce the ore to smaller sizes for further processing.
' Manufacturing High-quality Cubical Aggregates
In the production of concrete and asphalt, where the shape and size of the aggregate are critical, impact crushers are valued for their ability to produce precisely shaped end products.
' Secondary and Tertiary Crushing
Offering high reduction ratios, impact crushers are often used in secondary and tertiary crushing to create finer materials efficiently.
' Processing of Low-Abrasion Materials
Impact crushers are an excellent choice for less abrasive materials like limestone. They provide a higher level of material control during the crushing process.
' Demolition and Construction Waste Recycling
Beyond traditional aggregate uses, impact crushers are essential in recycling operations. They transform demolition waste into usable forms for new construction, effectively contributing to industry sustainability.
Choosing the right impact crusher for your project requires carefully assessing various critical factors. Here's what you need to consider:
1. Material Characteristics: Understand the type of material you will be processing, including its hardness, abrasiveness, and moisture content. This will determine the suitability of the crusher type and its wear parts.
2. Feed Size and Output Requirements: Consider the maximum size of the feed material and the desired output size. This will influence the choice between a Horizontal Shaft
Impactor (HSI) and a Vertical Shaft Impactor (VSI) and the crusher's size and configuration.
3. Capacity Needs: Identify your production capacity requirements. The throughput capacity of the crusher must match your project scale.
4. End Product Specification: The desired shape and size of the end product will affect your choice. VSIs are typically better for achieving a consistent and precise product shape.
5. Operational Considerations: Evaluate the impact of the crusher's energy efficiency, ease of maintenance, and operational costs. These factors will greatly affect the overall cost-effectiveness of the operation.
6. Mobility Requirements: Determine if the crusher needs to be mobile to move around the site or between sites. Portable crushers offer flexibility but may have capacity or efficiency trade-offs.
7. Environmental Compliance: Ensure that the impact crusher meets all local environmental regulations, especially if recycling or waste processing is a primary function.
8. Accessory Compatibility: Consider the compatibility with other equipment, such as feeders, conveyors, and screening machines, for an efficient operation.
9. Manufacturer's Support and Warranty: Look for reliable manufacturers with good after-sales support and warranty policies. This can significantly reduce downtime and maintenance costs over the crusher's life span.
Mobile impact crushers are the portable versions of traditional impact crushers. They offer the same benefits and capabilities as their stationary counterparts but with added mobility and convenience. This makes them popular for on-site crushing in construction, demolition, and recycling applications.
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