May. 13, 2024
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Rock Crushing Overview
It is typical to utilize a variety of crushers within a project, set up as stations in a circuit format. Frequently, primary, secondary, tertiary, and quaternary stations are installed to achieve the desired rock size, shape, and consistency.
Understanding the required fineness of your final output and the feed requirements of your tertiary or final reduction crushing station can guide how much reduction is necessary at this stage. Compression-style jaw, cone, impact crushers, and gyratory crushers are commonly used as primary crushing equipment.
Impact-style crushers like VSIs and horizontal shaft impactors (HSIs) break material by the impacting forces of wear parts such as blow bars and impact plates. These machines might require frequent part changes and can generate considerable dust, which can be problematic on certain worksites.
1. Primary Crushing
A primary crusher is essential for the success of your plant, serving as the first stage in a crushing circuit after extraction from a mine site or delivery to the RAP processing plant. Primary crushing reduces material to a size manageable for the secondary crusher. Typically, the minimum setting on most primary crushers is about 4 to 6 inches. Jaw, cone, impact crushers, and gyratory crushers are often appropriate as primary crushing equipment.
2. Secondary Crushing
When it comes to secondary crushing, reduction ratios are crucial. Knowing the desired final output size and the feed requirements of your tertiary or final reduction crushing station will help determine the extent of reduction needed at this stage. Cone crushers are frequently used at secondary crushing stations for their versatility and productivity when operated at consistent choked settings.
3. Tertiary/Quaternary/Final Reduction Crushing
The tertiary, quaternary, or final reduction stage aims to produce rock or material that is market-ready. There could be overlaps between stages regarding which crusher styles are most effective.
Stedman Machine
Stedman crushers are designed for maximum feed size, target output size, and total capacity. They can be used as cement crushers, mineral crushers, and more. Each size reduction project requires a comprehensive evaluation to optimize production and minimize operating costs.
Kemper Equipment
Jaw crushers, also known as rock breakers, are used to break larger, harder materials and exhibit less wear and tear compared to impact-style rock crushers. Kemper gyratory crushers feature a conical head and concave surface and break apart material by compression. They are often used in primary aggregate crushing stations but can also be utilized in secondary applications.
Impact-style crushers are best suited for less abrasive rocks like limestone. These machines break material with the impact forces of certain wear parts, such as blow bars and impact plates. They are sometimes used to achieve a cubical product after utilizing another type of rock crusher.
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ELRUS Aggregate Systems
ELRUS manufactures crushing equipment for the aggregate, mineral, mining, and recycling industries. The product line includes ELRUS jaw crushers, Sandvik cone and impact crushers in portable, modular, and stationary configurations to suit individual needs.
Metso Outotec
Metso Outotec is a leader in sustainable technologies, delivering end-to-end solutions and services for the aggregates, minerals processing, and metals refining industries. They enhance customer energy and water efficiency, boost productivity, and reduce environmental risks through their product and process expertise.
Eagle Crusher
Eagle Crusher is a global leader in manufacturing heavy-duty impact crushers, portable crushing and screening plants, jaw crushers, cone crushers, hammermills, and conveyors for the recycling, aggregate, and sand and gravel industries. The company is known for its innovative, quality products and exceptional aftermarket service and support.
At Mellott, we’ve been working with rock crushers for decades.
We’re proud to sell and service a range of industry-leading rock crushers. From jaw crushers to cone crushers and from stationary plants to mobile crushers, we offer a selection of models and parts that can suit any rock crushing need – so we have a wide-ranging familiarity with the industry’s leading brands.
You can view a full selection of the brands we offer – including new and used rock crushers here and parts – at this link.
If you’re looking for more information as you search for the ideal rock crusher, here are the brands you should review:
Metso has been a go-to choice since 1868, although it wasn’t branded as Metso until a merger in 1999. Metso offers a range of jaw crushers, gyratory crushers, cone crushers, and impact crushers optimized for any size reduction need. A Metso machine is a solid option for primary rock crushers or mobile plants.
Superior has been innovative since 1972 with their variety of equipment, including conveyors, crushers, and portable plants. They evolve their equipment constantly to meet industry needs.
Pegson was known for its dependable lines of jaw crushers and cone crushers. Though headquartered in the UK, American distributors have facilitated the provision of Pegson machines on this side of the Atlantic for decades. While rebranded to Powerscreen by parent company Terex, Pegson crushers are still available for resale.
Cedarapids, also owned by Terex, remains on the market with modular crushers designed to be flexible in applications, making setup efficient. Their machines include portable crushers, jaw crushers, cone crushers, and surge bins, offering excellent capabilities across various applications.
Home to the number one portable crusher in the world, Eagle Crusher supports the industry with its extensive catalog of equipment options, including heavy-duty impact crushers, portable crushing and screening plants, and conveyors.
Sandvik, a Swedish company, offers mining jaw crushers, cone crushers, impact crushers, roll crushers, and primary gyratory crushers for mining, quarrying, and aggregate production. They have extensive expertise covering a broad range of applications.
Allis Chalmers, although dissolved into several entities, has its rock crushers and parts still available for resale.
The Symons brothers are credited with designing the first spring cone crusher in the late 1940s. Today, Symons refers to a type of crusher, although it was the original brand. Metso has distributed Symons crushers worldwide, with some models being upgraded or replaced as technology advances.
Extec was a prominent brand for mobile crushing machines, having a network of global distributors. Though acquired by Sandvik in 2007, Extec crushers are still available for resale.
We hope this information has been helpful as you consider your rock crushing needs.
If you’d like more insight into any of these brands, get in touch with us. At Mellott, we have experience servicing a broad range of rock crusher brands, including all those listed here. We excel at navigating all components of rock crusher selection, setup, and maintenance.
For guidance in selecting and servicing a machine that fits your needs, get in touch with us today online or at 855.554.1606.
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