The Ultimate Buyer's Guide for Purchasing vertical shaft impact crusher

The Importance of Choosing a Mobile Rock Crusher

Before we get too far into the details, consider what you’ll get out of your rock crusher. These machines are excellent additions to many job sites, as they can help mitigate the skyrocketing costs of raw materials and support more eco-friendly construction practices — a win-win in the bid process and addition to your bottom-line profitability.

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Rock crushers can convert old, unwanted materials, such as concrete, granite, asphalt, limestone and basalt, even glass into new base materials for further building. They often reduce or eliminate the need for raw materials. When you reuse old concrete or process stone, you save on costs through:

• Raw material requirements: Concrete and masonry materials have jumped 15% in price in alone. A rock crusher allows you to save on the costs of new materials by replacing them with recycled ones, giving you more control over project costs.
• Delivery costs: Getting material on-site can be expensive, particularly in rural locations. You can reduce or eliminate this cost by producing the material on the job site.
• Disposal costs: Getting rid of old materials often requires costs such as landfill tipping fees and hauling fees. You don’t need to dispose of reused materials, so you can say goodbye to those exploding costs. If you pay a lot of disposal or tipping fees, a rock crusher could pay for itself very quickly!
• More competitive bidding: Using recycled materials can make your bids more competitive through reduced costs and eco-friendly building practices, helping you earn more profitable jobs.
• Sold materials: Even if you can’t use your recycled materials in a certain job, you can always resell them to make additional profit.

Aside from costs, mobile rock crushers also help the planet by keeping recycled materials out of landfills and contributing to Leadership in Energy and Environmental Design (LEED) certification. Concrete is the most recycled material on earth! Understanding the advantages of small rock crushers can help you better align your purchase with your goals. Whether you’re after a cost-saving measure, an eco-friendly tool or a mix of both, a mobile rock crusher is a great pick.

Portable vs. Mobile vs. Stationary Rock Crushers

Rock crushers come in portable, mobile, and stationary options. Portable crushers refer to machinery on trailers with wheels for the maximum on portability. Mobile crushers are crushers on tracks, like models with built-in crawlers, and are valued due to their mobility once on site, especially in larger crusher machinery. They require prime moves to get them to the work site and sacrifice a bit in portability. Stationary crushing equipment is machinery that stays in place once commissioned like in traditional quarries and aggregate producing plants. Though we can provide even the largest crushing plant design in the world, Senya Crushers specializes in our ultra-portable MICRO rock crushers, small enough to be towed with just a pickup truck! They’re perfect for job sites with limited space, smaller amounts of materials to process, or remote sites though they are workhorses designed to handle larger, more permanent crushing jobs as well.

For many small and mid-sized projects, our ultra-portable MICRO rock crushers offer all the benefits of a larger machine alongside extensive flexibility, portability, not to mention affordability. They move the crushing plant to the rocks, bringing crushing capabilities on site. If you need larger processing capacity, mobile systems and portable systems alike can accommodate higher capacities as we builder crushers with a large range of output capacities. Many mid-sized portable options offer the best of both worlds. We also offer 3 in 1 and 4 in 1 systems incorporating primary and even secondary crushers accompanied by a screen plant on a single chassis able to be pulled with a prime mover.

Conclusion

Everyone would like a crusher where you can put a big piece in one end and get very small output on the other and is highly affordable as well. There simply is no such thing. The crushing business is a lot like milling steel down to size. It usually takes multiple crushers, crusher types, and processing machinery working together to get the desired result. Without a doubt, each crushing situation is unique. As we often say, “there are no shortcuts to bustin’ rocks!”

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It’s a primary crusher. The jaw crusher is a machine for crushing rocks and other hard and abrasive materials, such as granite, ores or recycled concrete, usually for industrial purposes. The crushing device consists of a fixed plate and a swing plate called jaws between which the rock is trapped and crushed. A motor and a belt transmit the movement to an eccentric shaft that drives the movable jaw by rotation. A spring returns this moving jaw to let the crushed materials gradually descend into the crusher. When the materials are small enough, they fall into the space between the crusher’s two jaws. The crusher breaks the rock into small stones that are used in particular for manufacturing concrete for construction and roads.

Jaw crushers use a rudimentary and reliable technology that does not require much maintenance or engineering knowledge. They are the most popular crushers in the world. Jaw crushers are particularly suitable when the main objective is to reduce large blocks into smaller pieces that can then be processed by other machines.

Advantages: 

• Low maintenance and operating costs because it has few moving parts
• Reduces the raw material to about 150 mm

Disadvantages: 

• Not suitable for small material requirements (smaller than 150 mm). If a smaller grain size is required it can be used in combination with other crushers.
• Not suitable for handling clay or metal mixed with rock.

Cone crushers, also known as conical crushers, break rock between an eccentric rotating head and a bowl. The rotating head is covered by a wear-resistant mantle. The large pieces are broken once between the two jaws, then they gradually descend into the crusher where they continue to be broken until the pieces are small enough to pass through the narrow opening at the bottom of the breaking space. A cone crusher can crush a variety of rocks, from medium to hard. The way a cone crusher operates is similar to how a gyratory crusher does, but in a cone crusher the slope in the breaking space is not as steep.

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Although it is known for its ability to crush hard and abrasive ores and rocks, the cone crusher is better suited for secondary crushing. It is designed to crush pre-dimensioned materials, generally of 100 mm, 150 mm or 200 mm, and provide finished products of small dimensions.

Advantages: 

• Sturdy construction
• High productivity
• Easy adjustment
• Low operational costs This type of crusher is equipped with a spring release system that protects it against overloads and allows uncrushable materials to pass through the crushing space without damaging the crusher.
• Inexpensive machine

Disadvantages: 

• The cone crusher cannot take material of all sizes. The materials must be pre-dimensioned for the crusher (usually 200 mm or less).
• The finished product is not homogeneous, which is an essential requirement for many material specifications.
• Not suitable for handling clay or metal mixed with rock.

Impact crushers can be used as primary crushers, secondary crushers or tertiary crushers depending on the size and technology. They are equipped with beaters, also called hammers, and impact plates. They operate in the following way: they are fed from the upper part, then the stones are hit by the hammers and projected towards the plates. The stone breaks on the plate and bounces back towards the hammers. The process is repeated until the stone reaches the desired size. Impact crushers are ideal for mixed materials. They can crush clay, dirt or metal mixed with the feed material, for example reinforcing bars, wire mesh or anchors. They can crush hard materials, but are especially suitable for soft to medium rocks. Impact crushers, also called hammer crushers, can have a horizontal shaft or a vertical axis.

Horizontal-shaft: generates a uniform cubic product. It can accept all feed inputs and ensure maximum productivity, both in primary and secondary crushing.

Advantages: 

• The impact makes it possible to better control the size of the crushing result, for example better cubic gravel.

Disadvantages: 

• Operating costs can be higher.
• It can have difficulty breaking small parts, as the crusher’s ability to break blocks is related to the energy accumulated by the stone upon impact with the hammer. This energy therefore depends on the speed of the hammer, but also on the mass of the stone.
• Wear of the beaters depends on the matter being crushed.

Vertical-axis: can create quality sands. It crushes the gravel even more finely because it breaks the most persistent bonds of the aggregate. This results in a sand with optimal consistency and shape, especially for concrete. This machine combines rotational energy with impact energy for crushing.

Advantages: 

• High production capacity
• High breakage rate
• Low energy consumption
• Uniform grain size

Disadvantages: 

• Can only be used to obtain fine finished products

While stationary crushers have the advantage of being sturdy, it can be advantageous to choose a mobile crusher to get the crusher closer to where the it is going to be needed. Wheeled crushers can be moved to a construction site using a truck. These units are generally autonomous and therefore do not require an additional diesel engine to operate. Crawler crushers are designed to be moved around constantly. They are more compact and weigh less than mobile wheeled crushers.

Mobile crushers perform the same types of crushing as stationary ones. For reasons of autonomy, they also include a hopper and a conveyor to feed the crusher, as well as a second conveyor to evacuate the final product.

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