Vertical shaft impact crusher is a type of crusher that operates in crusher plants. This type of crusher is designed for crushing hard and highly abrasive materials.
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Unlike many other crusher models, the Vertical shaft impact crusher is very efficient to crush small sized stones and mines. In addition, it is designed to break moist, watery or sticky mines to desired sizes.
Stone crushing and screening plants, known as crushing plants in short, are facilities where large-sized ores extracted from mines or stream beds are converted into smaller sizes. Sand production is required to obtain aggregate, which is the basic material of the construction industry. Sand is one of the main materials of concrete and can be manufactured by processing large-sized special stones in crushing facilities and reducing them to small sizes.
Crusher plant consists of several machines that can perform different operations together. Crushing is an important process in the plant and many types of crushers exist to perform for it. One of them is Vertical shaft impact crusher that has a rotor rotating at high speed to crush materials. It is able to crush moist or water-contacted stones as well as hard and highly abrasive stones. It provides important advantages to companies as well.
The Vertical shaft impact crusher can successfully crush almost all types of stones and ores, even materials with high abrasion rates. It runs in high-speed rotational motion. This type of crusher operates on the principle of the conversion the kinetic energy of the stones converts to the impact and crushing energy, not breaking the stones by the crusher’s own mechanisms.The material from the feeder rotates rapidly with the movement of the rotor to obtain high kinetic energy, and then is transferred to the crushing section. Here, kinetic energy is transformed into impact force, causing the stones to collide with each other and break. Therefore, the stone becomes smaller.
Impact crushers have a wide range of use whose examples are as follows:
It is one of the most preferred crusher models and can successfully shrink highly abrasive ore to a cubic rate of 0.5 mm.
Shaft crushers can be designed in different structures for the different needs of the enterprises. The one is the crusher with a fixed Vertical shaft impact. It is designed for long-term projects by taking part in large business areas. The fixed crusher is mostly preferred by companies producing at high capacity in same project area. It provides them significant cost advantages in terms of its performance and durability.
FABO Vertical shaft impact Crushers are designed in different models and capacities in order to crush the desired amount. FABO crushers are able to crush an average of 90 tons to 450 tons of stone per hour and shrink almost any medium-sized mine to a cubic rate of 0.5mm. (Vertical shaft crusher VSI-900 performs an average of 450 tons of crushing per hour. You can view the product here.)
Shaft crushers, which have a very wide range of work, belong to the tertiary crusher class. While FABO shaft crushers provide companies significant savings in terms of time and cost in long-term projects, they are also offered for sale with a 1-year warranty.
Crushing of the material coming from the feeding hopper is carried out by the rotor rotating at high speed. The stone in the cascading zone is thrown into the crushing zone through the distributor plate. Spare parts expenses are quite low in this crushing process, in which the method of colliding stones against each other is used. Some specifications of FABO vertical shaft impact crusher are given as follows:
Vertical shaft crushers have been designed by FABO engineers in such a way that the most efficiency is obtained with the least energy. They produce sand and stone chips at 0.5mm by breaking all kinds of medium-sized and hard materials. Some benefits offered by these machines are as follows:
FABO vertical shaft crushers are produced in high quality in accordance with European standards. They work on the principle of increasing efficiency by conserving energy. Vertical Shaft crusher is the least energy-consuming machine on the market since it is a highly engineering product designed as a result of long and wide R&D studies.
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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.
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.
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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.