Mining Stone Crushers
Crushers Equipment in Iran - Provided by FITCO
Crushing is the first stage in the grinding of the materials extracted from the mine. It is usually done in several stages, mainly in the primary and secondary crushers.
In the primary crushing, rocks up to 1.5 meters, are reduced to about 10 to 20 centimeters, while in the secondary stage, the product from the primary crusher is further reduced to about 0.5 to 2 centimeters.
As a top member of mining equipment supplier in Iran, FITCO Company offers various types of the best crushing equipment in Iran for its clients in cooperation with international partners.
Two Types of Crushing Process
- Open Circuit: In this method, the feed material passes through the crusher once, with no feedback loop. This approach is typically used in primary crushing, where uniformity of product size is less critical.
- Closed Circuit: Coarse materials are returned to the crusher for re-crushing to achieve the desired size.
FITCO provides the top-global brand for the cement, aggregates, recycling and mining industries, providing innovative solutions and sustainable success for its customers.
Types of Crushers at FITCO
- Primary Crushers: Primary crushers are heavy machines used mainly in open circuit operations. Main types of primary crushers are jaw crushers and gyratory crushers.
- Secondary Crushers: Secondary crushers come in three main types: cone crushers, roller crushers, and impact crushers.
Jaw Crusher
A jaw crusher has two jaws, one fixed and one movable jaw, between which materials are crushed by compressive force. As materials move downwards, they are subjected to increasing pressure, leading to crushing in the narrowing space.
Advantages:
- Suitable for crushing ores up to about one meter in size and for circuits where the importance of input size is greater than capacity.
- Has a relative advantage over gyratory crushers in handling high clay content.
- Can be installed either underground or on the surface
- Less expensive compared to gyratory crushers.
- Can be built in modular form for easy transportation.
Limitations:
- Requires strong foundations.
- Lower capacity compared to gyratory.
- Wear on jaw surfaces.
- Higher installation costs compared to gyratory type.
Cone Crushers
Cone Crusher which are similar to gyratory crushers but produce a finer product due to their smaller discharge width. They are used in intermediate and tertiary crushing stages.
Features:
- Available in standard and short-head models: standard for secondary crushing and short-head for tertiary stages.
- Adjustments are made based on the gap between the fixed body and the moving core, and the type of feed.
Applications:
- Secondary and tertiary crushing.
- Special cone crushers (known as gyradiscs) are used for producing finer products below 6 mm.
Roller Crushers
Roller Crusher Roller crushers are less commonly used and have been largely replaced by cone crushers. They are employed when the goal is to minimize fine production.
Applications:
- Suitable for brittle, sticky, or frozen materials like coal, lime and phosphate.
- Provides better performance compared to jaw and gyratory crushers for certain materials.
Gyratory Crusher
Gyratory Crusher Gyratory crushers are used in large plants where high capacity are desired. The gyratory crusher consists of a conical fixed body and a rotating central core. The angle between the body and the moving core is 20 to 30 degrees. Material is crushed in the gap between the stationary body and the rotating core.
Advantages:
- Higher capacity than jaw crushers.
- Suitable where capacity is more important than input size.
- Lower installation cost compared to jaw types.
- Direct loading with trucks, eliminating the need for a silo and feeder.
Limitations:
- High capital and maintenance costs.
- Less effective with high clay content materials.
High Pressure Grinding Rolls (HPGR)
HPGR stands for High Pressure Grinding Rolls. HPGR is increasingly used in iron ore processing as a substitute for ball mills or in combination with ball mills.
Operation:
HPGRs consist of two rotating rolls mounted on special bearings. Pressure is applied via a hydraulic system to one roll, increasing the pressure in the gap between the rolls, leading to crushing.
Hammer Crusher
Hammer crushers perform the crushing process via a rotating rotor and are used as primary or secondary crushers. The rotor has several rows of hammers that throw input material against the internal walls of the crusher.
Advantages:
- Effective for high crushing ratios and high production of fines.
- Can handle input sizes up to 1.5 meters.
- Provides a high reduction ratio of more than 40.
- Lower capital cost compared to jaw and gyratory crushers.
Limitations:
- High wear rate with materials containing more than 8% silica.
- High energy consumption.
- Requires a feeder.