Category: Stationary Crushers

A Spring Cone Crusher is a type of secondary or tertiary crushing equipment widely used in mining, metallurgy, construction, and aggregate production. It is designed to crush hard and medium-hard materials like iron ore, limestone, granite, basalt, and quartz.

Key Components & Working Principle
1. Crushing Chamber: Consists of a fixed concave (outer liner) and a movable mantle (inner cone) that gyrates under eccentric motion.
2. Spring Safety System: A set of springs around the frame acts as an overload protection mechanism. If uncrushable material enters the chamber, the springs compress to widen the discharge opening and release the foreign object, preventing damage.
3. Eccentric Shaft & Rotation: Driven by a motor via belts/pulleys, the eccentric shaft causes the mantle to oscillate, crushing material against the concave.
4. Discharge Adjustment: The gap between the mantle and concave can be adjusted to control output size (coarse to fine).

Advantages
– Reliable Overload Protection: Springs absorb shock from tramp iron or hard materials.
– High Crushing Efficiency: Suitable for medium/fine crushing with good particle shape.
– Simple Structure & Low Maintenance: Fewer hydraulic components compared to hydraulic cone crushers.

Limitations
– Less automated than hydraulic cone crushers (e.g., no real-time

justment).
– Lower capacity compared to modern hydraulic models for large-scale operations.

Applications
– Mining (iron ore, copper ore).
– Quarrying (limestone, granite).
– Road construction aggregates.

Comparison with Hydraulic Cone Crusher
| Feature | Spring Cone Crusher | Hydraulic Cone Crusher |
|–|–|–|
| Overload Protection | Mechanical springs | Hydraulic cylinders |
| Adjustment | Manual | Automatic (hydraulic) |
| Cost | Lower | Higher |
| Automation | Limited | Advanced (e.g., PLC control)|

For modern high-capacity or automated crushing plants, hydraulic cone crushers are often preferred. However, spring cone crushers remain cost-effective for small-to-medium operations requiring robustness and simplicity.

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A CS Cone Crusher (short for Cone Crusher, Symons type) is a high-efficiency spring cone crusher developed based on the principles of laminating crushing and multi-breaking with less grinding. It is widely used in mining, metallurgy, construction, road building, and chemical industries for crushing hard and medium-hard materials like iron ore, copper ore, limestone, quartz, granite, basalt, and more.

Key Features of CS Cone Crusher:
1. High Efficiency & Performance
– Optimized crushing cavity design ensures higher capacity and better product shape.
– Suitable for secondary and tertiary crushing stages.

2. Reliable Hydraulic Adjustment & Overload Protection
– Hydraulic system for easy adjustment of discharge opening.
– Automatic overload protection prevents damage from uncrushable materials.

3. Stable Structure & Durable Components
– Reinforced main frame and high-quality alloy steel components ensure long service life.
– Advanced sealing system reduces dust contamination.

4. Good Particle Shape
– Laminated crushing principle produces well-shaped cubic end products.

5. Easy Maintenance
– Modular design allows quick replacement of wear parts.
– Simple hydraulic or manual adjustment options.

Technical Parameters (Example Models)
| Model | Max Feed Size (mm) | Discharge Range (mm) | Capacity (t/h) | Motor Power (kW) |
|-|-|-|-||
| CS75 | ≤115 | 9-38 | 45-91 | 75 |
| CS160 | ≤178 | 13-38 | 72-172 | 160 |
| CS240 | ≤240 | 19-51 | 181-327 | 240 |

Applications
– Secondary & tertiary crushing in mining and aggregates.
– Crushing hard rocks in quarrying operations.
– Construction waste recycling.
– Cement and chemical industries.

Comparison with Other Crushers
– Compared to a Jaw Crusher, the CS Cone Crusher provides finer output but requires a primary crusher first.
– Compared to an Impact Crusher, it offers better particle shape but may have higher wear costs in abrasive conditions.

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An Impact Crusher is a type of crushing machine that uses impact force to break down materials. It is widely used in mining, construction, and recycling industries to crush rocks, concrete, and other hard materials into smaller, more manageable sizes.

How Does an Impact Crusher Work?
1. Feeding: Material enters the crusher through a feed hopper.
2. Rotor & Blow Bars: A high-speed rotor with attached blow bars (hammers) strikes the incoming material.
3. Impact Crushing: The material is thrown against impact plates (or aprons), where it breaks due to the force of impact.
4. Adjustable Settings: The gap between the rotor and impact plates can be adjusted to control the output size.
5. Discharge: Crushed material exits through the discharge opening.

Types of Impact Crushers
1. Horizontal Shaft Impact Crusher (HSI)
– Uses a horizontal rotor with blow bars.
– Ideal for softer materials like limestone and recycled concrete.
– Commonly used in aggregate production.

2. Vertical Shaft Impact Crusher (VSI)
– Uses a vertical rotor with high-speed impellers.
– Produces finely shaped cubical aggregates (sand-making).
– Often used in sand production and fine crushing.

Advantages of Impact Crushers
✔ High reduction ratio (up to 20:1)
✔ Good particle shape (cubical output)
✔ Versatile for soft to medium-hard materials
✔ Lower operational costs compared to jaw or cone crushers

Common Applications
– Quarrying & mining (limestone, granite, etc.)
– Recycling (concrete, asphalt demolition waste)
– Aggregates production for construction
– Sand manufacturing (VSI crushers)

Limitations
❌ Not ideal for very hard or abrasive materials (e.g., basalt) without wear-resistant linings.
❌ Higher wear on blow bars and impact plates compared to compression crushers.

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A Secondary Impact Crusher is a type of crushing machine used in aggregate production, recycling, and mining operations to reduce the size of materials after primary crushing. It is designed to handle softer to medium-hard materials (e.g., limestone, asphalt, concrete, demolition waste) and produce a more uniform, cubical end product compared to primary crushers.

Key Features of a Secondary Impact Crusher:
1. Purpose:
– Further reduces material size after primary crushing (e.g., jaw or gyratory crusher).
– Ideal for producing high-quality, well-shaped aggregates for construction (roads, concrete).

2. Working Principle:
– Uses high-speed impact forces (rotor with hammers/blow bars) to break materials.
– Material is fed into the crushing chamber and struck by rotating blow bars before being thrown against impact aprons/liners for additional fragmentation.

3. Advantages:
– Produces a more uniform, cubical product (better for asphalt and concrete).
– Higher reduction ratio than cone crushers in certain applications.
– Adjustable output size via hydraulic or mechanical settings.
– Handles moderately abrasive materials efficiently.

4. Disadvantages:
– Higher wear on blow bars compared to compression crushers (e.g., cone crushers).
– Not ideal for very hard or highly abrasive materials (e.g., granite).

5. Common Applications:
– Crushing limestone, recycled concrete, asphalt, and demolition debris.
– Aggregate production for road base, railroad ballast, and construction fill.

6. Types of Secondary Impact Crushers:
– Horizontal Shaft Impactors (HSI): Most common for secondary crushing; material is fed horizontally into the rotor.
– V

ical Shaft Impactors (VSI): Used for shaping and fine crushing (more common in tertiary stages).

Comparison with Other Crushers:
| Feature | Secondary Impact Crusher | Cone Crusher | Jaw Crusher |
||-|–|-|
| Crushing Method | Impact force | Compression | Compression |
| Output Shape | Cubical | Flaky/Elongated | Variable |
| Wear & Cost | Higher wear on blow bars | Lower wear parts | Moderate wear |
| Best

A Primary Impact Crusher is a heavy-duty machine used in the first stage of crushing (primary crushing) to break large rocks, ores, or other hard materials into smaller, more manageable pieces. Unlike jaw crushers, which use compression force, impact crushers utilize high-speed impact to fracture materials.

Key Features of Primary Impact Crushers:
1. High Reduction Ratio – Capable of reducing large feed sizes (up to 1-2 meters) into smaller fragments in a single pass.
2. Horizontal Shaft Design – Uses rotating hammers or blow bars to strike and throw material against breaker plates.
3. Versatility – Can handle soft to medium-hard rocks (limestone, gypsum, coal) and some abrasive materials.
4. Adjustable Output Size – The gap between the rotor and impact aprons can be adjusted to control product size.
5. High Throughput Capacity – Suitable for high-production quarrying, mining, and recycling applications.

Advantages Over Other Primary Crushers:
– Better cubical-shaped end product compared to jaw crushers.
– Higher reduction ratio in a single stage.
– Effective for softer materials where compression crushers may generate excessive fines.

Common Applications:
– Quarrying & Aggregates (limestone, gravel)
– Cement Industry (crushing raw materials)
– Recycling (concrete, asphalt demolition waste)
– Mining (primary reduction of ore)

Popular Models & Manufacturers:
– Metso Nordberg NP Series
– Sandvik CI Series
– Hazemag AP-PH Series
– Kleemann MR 110/130 EVO

Considerations When Choosing a Primary Impact Crusher:
✔ Feed size & material hardness
✔ Desired output size & production capacity
✔ Maintenance requirements (wear parts like blow bars)
✔ Energy efficiency & operating costs

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A jaw crusher is a primary crushing machine used in mining, quarrying, and construction industries to reduce large rocks, ores, or other hard materials into smaller, more manageable pieces. Here’s a detailed breakdown:

How It Works
1. Crushing Mechanism:
– A jaw crusher consists of two vertical jaws—one fixed (stationary) and one movable (swing jaw).
– The movable jaw exerts force on the material by pressing it against the fixed jaw.
– Material is crushed progressively until small enough to pass through the bottom gap (discharge opening).

2. Key Components:
– Fixed Jaw Plate: Attached to the crusher frame.
– Movable Jaw Plate: Driven by an eccentric shaft (pitman) that creates an elliptical motion.
– Toggle Plate: Safety mechanism to protect the crusher from overload.
– Flywheel: Stores energy for consistent crushing force.

Types of Jaw Crushers
1. Blake (Double Toggle): Older design with a pivoted swing jaw; robust but less efficient.
2. Dodge (Single Toggle): Movable jaw pivots at the bottom; simpler but limited in capacity.
3. Universal (Overhead Eccentric): Modern single-toggle design with higher efficiency and adjustability.

Applications
– Primary crushing of hard materials (granite, basalt, iron ore).
– Recycling concrete and demolition waste.
– Laboratory-scale crushing for research.

Advantages
– Simple structure, low maintenance.
– High reduction ratio (typically 6:1 to 8:1).
– Handles abrasive materials well.

Disadvantages
– Less efficient than gyratory crushers for high-capacity needs.
– Wear-prone parts (jaw plates) require regular replacement.

Maintenance Tips
– Regularly check jaw plates for wear and replace as needed.
– Lubricate bearings and eccentric shafts to prevent overheating.
– Monitor discharge settings to ensure optimal particle size output.

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The JC Series Jaw Crusher is a modern, high-performance primary crushing machine designed for tough and abrasive materials. It is widely used in mining, quarrying, construction, and recycling industries due to its robust structure, efficiency, and reliability. Below are its key features, advantages, and applications:

Key Features:
1. Advanced Crushing Technology
– Optimized cavity design and motion dynamics for higher capacity and better reduction ratio.
– Deep “V” crushing chamber minimizes blockages and enhances throughput.

2. Durable Construction
– High-quality materials (e.g., heavy-duty cast steel frame, forged eccentric shaft) ensure longevity.
– Bolted (non-welded) frame design reduces stress concentrations.

3. Adjustable Discharge Setting
– Hydraulic or mechanical adjustment options for quick and precise gap settings.

4. Safety & Maintenance
– Easy-to-replace wear parts (jaw plates, toggle plates).
– Centralized lubrication system for smooth operation.

5. Energy Efficiency
– Low power consumption per ton of crushed material.

Advantages:
– Higher crushing capacity compared to traditional jaw crushers.
– Reliable performance in extreme conditions (hard rock, recycled concrete).
– Reduced downtime due to simplified maintenance.
– Compatible with automated control systems (e.g., PLC).

Technical Specifications (Example Models):
| Model | Feed Opening (mm) | Max Feed Size (mm) | Capacity (t/h) | Power (kW) |
|-|-|–|-||
| JC110 | 1100×850 | 930 | 150–300 | 90–110 |
| JC130 | 1300×1000 | 1100 | 250–500 | 160–200 |

*(Exact specs vary by manufacturer; consult product manuals.)*

Applications:
– Primary crushing of granite, basalt, iron ore, limestone.
– Demolition waste recycling.
– Aggregates production for construction.

Manufacturers:
Leading brands offering JC Series crushers include:
– Liming Heavy Industry (China)
– Sandvik *(similar “Jawmaster” series)*
– Metso/Nordberg *(C-Series equivalents)*

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The HJ Series Jaw Crusher is a high-performance crushing machine developed by Liming Heavy Industry, designed for primary crushing in mining, quarrying, and construction applications. It combines advanced technology, robust construction, and energy efficiency to deliver superior crushing performance.

Key Features of HJ Series Jaw Crusher:
1. Advanced Crushing Technology
– Optimized cavity design and deep crushing chamber improve capacity and efficiency.
– Higher crushing ratio compared to traditional jaw crushers.

2. Energy Efficiency
– Equipped with a high-efficiency motor and optimized kinematics for reduced energy consumption.
– Lower operating costs due to improved power utilization.

3. Durable Construction
– High-quality steel components ensure long service life under heavy-duty conditions.
– Reinforced frame and movable jaw structure enhance reliability.

4. Adjustable Discharge Setting
– Hydraulic or mechanical adjustment options for precise control over output size.
– Flexible for different production requirements.

5. Low Noise & Vibration
– Advanced damping technology reduces operational noise and vibration, improving workplace safety.

6. Easy

ntenance
– Simplified design with accessible parts for quick inspection and replacement.

Applications:
– Primary crushing in mining (iron ore, gold, copper).
– Quarrying (granite, basalt, limestone).
– Construction waste recycling (concrete, asphalt).

Technical Specifications (Example Model: HJ110)
| Parameter | Value |
|||
| Feed Opening | 1100×650 mm |
| Max Feed Size | ≤800 mm |
| Capacity | 150-300 t/h |
| Power | 90-110 kW |
| Weight | ~20 tons |

Advantages Over Traditional Jaw Crushers:
✔ Higher throughput with lower energy consumption.
✔ Improved wear resistance for longer lifespan.
✔ Better particle shape with optimized crushing motion.

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A High Frequency Screen is a specialized vibrating screen designed for fine particle separation, widely used in industries like mining, mineral processing, and recycling. Here’s a detailed breakdown:

Key Features:
1. High Vibration Frequency (3,000–7,200 RPM):
– Enables efficient separation of fine particles (typically <0.075 mm) by overcoming surface tension and clogging.

2. Small Mesh Openings:
– Uses fine screens (often polyurethane or stainless steel) to achieve precise grading or dewatering.

3. Low Amplitude:
– Gentle vibration prevents screen damage while maintaining material flow.

4. Applications:
– Mineral Processing: Sizing silica sand, iron ore, coal, etc.
– Aggregates: Classifying crushed stone or sand.
– Recycling: Separating metals, plastics, or waste materials.
– Dewatering: Removing water from slurries (e.g., tailings).

Advantages:
– Higher efficiency for fine materials compared to traditional screens.
– Compact design with modular screens for easy maintenance.
– Reduced blinding/pegging due to intense vibration.

Types:
– Linear Motion: For dry or wet screening at medium

acity.
– Elliptical Motion: Combines high frequency with stratification for better accuracy.

Manufacturers:
Leading brands include Derrick Corporation, Metso Outotec, Schenck Process, and Haver & Boecker.

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An Electromagnetic Vibrating Feeder is a type of feeding equipment that uses electromagnetic forces to generate vibrations, transporting bulk materials in a controlled manner. It is widely used in industries such as mining, metallurgy, cement, chemical, food processing, and pharmaceuticals for conveying granular or powdered materials.

Working Principle
1. Electromagnetic Drive System:
– An electromagnet generates an alternating magnetic field when powered by an AC or half-wave rectified current.
– This causes the armature (attached to the feeder tray) to vibrate at high frequency (typically 50-60 Hz or 3000-3600 vibrations per minute).

2. Resonance Principle:
– The feeder operates near its natural resonant frequency for high efficiency with minimal energy consumption.
– Springs (leaf or helical) amplify and direct the vibrations for smooth material flow.

3. Material Movement:
– The vibrating motion (linear or elliptical) moves material along the trough via micro-throws at high speed.

Key Components
– Electromagnet – Generates pulsating force.
– Trough/Feeder Pan – Carries the material.
– Spring System – Supports and amplifies vibrations.
– Control Unit – Adjusts vibration intensity (amplitude) via voltage regulation.

Advantages
✔ High precision & controllable feed rate
✔ Low power consumption (energy-efficient)
✔ No moving parts → Minimal maintenance
✔ Compact & quiet operation
✔ Suitable for harsh/dusty environments

Applications
– Feeding crushers, screens, and conveyors in mining/aggrega

.
– Dosing materials in chemical & food processing.
– Packaging & weighing systems.
– Foundry sand handling.

Selection Considerations
1. Material Properties – Size, density, moisture content.
2. Capacity Requirements – Feed rate (tons/hour).
3. Trough Design – Open/closed, lined (for abrasives).
4. Power Supply – Voltage/frequency compatibility.
5. Control Options – Variable speed for adjustable flow.

Common Issues & Solutions
– Material Clogging? → Adjust amplitude or install a steeper trough.
– Excessive Noise? → Check spring condition and fasteners.
– Inconsistent Flow? → Verify voltage stability and material buildup.

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