Principles, Advantages and Disadvantages of Mainstream ...

Crushing equipment is an indispensable part of crushing, sand making, grinding, and other processes. However, there are many types of crushers on the market, so how do choose suitable and satisfactory products? First of all, you need to know the applicable conditions, advantages and disadvantages of these crushers.

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Crushing method

The crushing method of the crusher is divided into squeezing, splitting, crushing, shearing, impact or hammer, etc. Generally, there is no single action mode but a mix of multiple action modes.

Squeezing and crushing:The working face of the crushing machine applies pressure to the material sandwiched between it, and the material is crushed when the compressive stress on the material reaches the limit of its compressive strength.

Splitting, shearing and crushing:The edges of the crushing working face are wedged into the material to generate tensile stress inside. When the value exceeds the tensile strength limit of the material, the material splits and locally produces powder at the point of contact between the sharp edge and the material.

Bending, breaking and crushing:The materials sandwiched between the working surfaces, such as simply supported beams or multi-supported beams subjected to concentrated forces, are mainly subjected to bending stress, but are subject to splitting at the contact point of the working surface.

Squeezing and shearing:A combination of squeezing and shearing.

Impact crushing:Impact crushing includes the impact of the high-speed moving crusher on the material to be crushed, the impact of the high-speed moving material on the fixed wall and the mutual impact of the moving materials.

Analysis of the crushing mechanism, advantages and disadvantages of different crushers

Crushers can be divided into three categories according to the granularity of feed and product:

Coarse crusher:crush from ~500mm to 350~100mm;

Medium crushing crusher:crushing from 350~100mm to 100~40mm;

Fine crusher:crush from 100~40mm to 30~10mm.

Crushers can be divided into different working principles and structural features:

1. Jaw crusher

The jaw crushing work is intermittent, and the rock material is squeezed to complete the crushing by the swing of the fixed jaw and the movable jaw. Simple pendulum jaw crusher are rarely used in practice now, mainly compound pendulum jaw crusher.

Application:It is suitable for a wide range of materials, both soft and hard, especially the coarse and medium crushing of hard stones.

Advantages:Simple structure, reliable work, lighter weight, cheap price, small size, low configuration height, large feed opening size, easy adjustment of the discharge opening, simple maintenance, and economical operating costs.

Disadvantages:Easy wear of liner, high content of needle flakes in the product, and feeding equipment are generally required.

2. Cone crusher

The work of the cone crusher is continuous, and it crushes the stone by the eccentric movement of the moving cone. At the same time, due to the tangential movement of the moving cone and the fixed cone, the stone is also subjected to shearing and grinding. Therefore, its working mechanism It is a combination of extrusion, shearing, and milling methods.

Application:Mainly used for medium or fine crushing of various stone materials. At the same time, according to its different structure (suspended shaft type and supporting shaft type), it can also be used for coarse stone crushing (suspended shaft type is used less).

Advantages:large crushing ratio, high efficiency, low energy consumption, less dust, uniform product size, stable work, low failure rate, and not easy to be crushed.

Disadvantages:The more complicated structure and maintenance, high body and the expensive price.

3. Impact sand making machine

The work of the impact sand making machine is continuous. It uses high-speed moving materials to strike iron, strike each other, and friction between the materials to crush. There are two crushing methods: crushing between stones and crushing between stone and plate.

Application:Crushing between stones is suitable for abrasive materials with medium hardness and above. The finished product has a better grain shape and slightly more powder content. Crushing between stone and plate is suitable for materials with low abrasiveness below medium-hardness, with higher crushing efficiency, higher wear cost of the peripheral guard plate, and poorer grain shape of the finished product.

Advantages:low energy consumption, high capacity, large reduction ratio, the small size of the equipment, easy operation, convenient installation and maintenance. It has a shaping function, cubic product, large bulk density, and great less wear of the machine's impact plate during operation.

Disadvantages:The complicated maintenance and high cost. Generally, the maximum feed size does not exceed 60mm, which is suitable for fine crushing and sand making.

4. Hammer crusher

The hammer crusher also works continuously, using the hammerhead on the high-speed rotating rotor to crush the stone.

Application:Suitable for medium and fine crushing of medium and low hardness and non-abrasive stones (compressive strength less than 100MPa). When there are grate bars, it can also be used for sand making but it has been rarely used.

Advantages:large reduction ratio, high output, and more fine materials.

Disadvantages:The hammerhead wears quickly and needs to be replaced frequently. The large work dust and viscous materials with a raw material moisture content of more than 12% cannot pass effectively.

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5. Impact crusher

Impact crusher is a machine that uses impact energy to crush materials. Adjusting the gap between the impact frame and the rotor can achieve the purpose of changing the size and shape of the material discharged.

Application:Mainly used for medium crushing and fine crushing of stones below medium hardness, and the shape of the crushed stones is better.

Advantages:Small size, simple structure, uniform product size, selective stone crushing, and high capacity.

Disadvantages:The flat hammer and the impact plate are particularly easy to wear, especially for crush hard rocks, which are more severely worn and need to be replaced frequently. It is not suitable to crush plastic and viscous materials.

Today&#;s construction and mining tasks require the need for crushers that play a crucial role in reducing large rocks into smaller, manageable pieces for further processing, and understanding their key differences is essential for making the best choice for your project needs. At first glance, it&#;s obvious that stationary equipment is fixed, while mobile equipment can be moved to the construction site. However, let's dive into the specifics, discussing each type's advantages and disadvantages!

What is a Mobile Rock Crusher

A mobile rock or stone crusher is a portable machine designed to reduce the size of rocks and stones. These crushers are mounted on a mobile platform or chassis, allowing them to be transported easily from one location to another. Mobile crushers can be wheeled or tracked and operate in a variety of environments, making them highly versatile and convenient for projects that require frequent relocation. 

As the authorized dealer of Powerscreen, you can get to choose from our fleet of brand-new Powerscreen jaw crushers, known for their robust design, high performance, and efficiency in mobile applications. You also benefit from comprehensive warranties, access to genuine spare parts, and after-sale services.

Powerscreen Premiertrak 450 jaw crusher available for sale at almarwan.com 

What is a Stationary Crusher

A stationary crusher, also known as a fixed crusher, is designed to stay in one place throughout its operating life. These crushers are typically installed in a designated area at a mining or quarry site and remain there until the end of the project's life cycle. Stationary crushers are known for their larger capacity and ability to handle massive volumes of material.

Large-scale stationary crushing and screening plant. Image credit: mesto.com

Pros and Cons of Stationary and Mobile Crushers

A number of features characterizes both mobile and stationary crushers, although they share the same basic function: crushing rocks into smaller pieces.

What makes mobile crushers stand out?

Mobility: Mobile crushers often need to cool down every 10 to 15 minutes, which can impact their speed and travel distance. However, their ability to move directly on-site helps reduce transportation costs for materials that need further processing. This mobility is especially useful in rough terrains where cranes have limited access to the site.

Quick Setup: Due to the fast installation, they can be operational quickly and are ideal for temporary projects, or when starting operations rapidly is crucial.

Space-saving and Integrated Systems: Mobile equipment has a compact structure, and integrates a feeder, belt conveyor, crusher, and vibrating screen, all in one frame, which reduces the space requirements. 

Reduced Environmental Impact: By minimizing material transportation, mobile crushers can help process materials directly at the extraction site. Less hauling means fewer carbon emissions and a smaller footprint.

Cost Efficient: Its mobility reduces the need for additional infrastructure, such as haul trucks, and it requires less transporting vehicles than the stationary crusher. For example, you may need two machines to transport a mobile crusher to the mining site whereas around 10 equipment are required to dismantle and install the stationary crusher.

Versatile Applications: Suitable for a wide range of crushing tasks, including recycling, demolition, and small-scale mining operations.

Powerscreen Premiertrak 420E jaw crusher is a mid-range crusher. Image credit: powerscreen.

Limitations of mobile crushers

Lower Capacity: Generally have a lower production capacity due to the smaller size and lighter build that limit the crushing mechanisms that can be used, resulting in less crushing force.

Limited Customization: Less room for customization compared to stationary setups.

Powerscreen Premiertrak 450 used in quarrying, demolition, recycling, and mining applications.

What makes stationery crushers stand out?

High Production Capacity: Able to handle large volumes of material, making them suitable for major projects and high-demand applications.

Customization: Can be tailored to meet specific project requirements and integrated into larger processing systems.

Consistency: Provide a steady and reliable output, essential for continuous, large-scale production.

Economies of Scale: Higher initial investment can be offset by lower operating costs and increased production efficiency over time.

Durability: Built to last, stationary crushers are designed to withstand the rigors of high-capacity crushing tasks.

Static crushers are ideal for high-demand applications. Image credit: zndmixer.com

Disadvantages of Stationary Crushers:

Lack of Mobility: Once installed, these crushers are fixed in place, requiring significant effort and cost to relocate.

Longer Setup Time: Installation is more time-consuming and involves significant site preparation.

Higher Initial Cost: The initial setup and infrastructure costs can be higher due to the need for foundations and permanent installations.

Decision-Making Considerations

When deciding between a mobile rock crusher and a stationary crusher, consider the following factors to ensure you make the best choice for your project:

Project Size and Duration

For projects that are short-term or involve smaller volumes of material, mobile crushers are often the best choice due to their quick setup and ease of relocation. They allow for rapid deployment and can be operational within hours, which is ideal for projects with tight timelines. For example, a road construction project requiring temporary crushing of asphalt might benefit from a mobile crusher. On the other hand, large-scale, long-term projects, such as a quarry producing aggregate for several years, benefit more from the high capacity and efficiency of stationary crushers. These crushers can handle larger volumes over extended periods, making them more suitable for sustained, high-output operations.

Premiertrak 600E mobile crusher is tailored for large projects due to its spacious chamber. Image credit: powerscreen.

Material Types and Sizes

Different types of materials and their sizes significantly influence the choice of crushing equipment. Mobile crushers offer versatility in handling a variety of materials, from concrete and asphalt to natural stones and minerals. They can quickly adapt to different crushing needs on-site. Stationary crushers, however, are ideal for handling large, heavy, and abrasive materials that require a consistent and powerful crushing force.

Fixed stone crusher offers up to 500 tons crushing capacity per hour. Image credit: machinery park

Initial and Operating Costs

Initial and operating costs are crucial factors to consider. Mobile crushers generally have lower initial costs due to their minimal infrastructure requirements and quicker setup times. They also offer operational cost savings by reducing material transportation needs. However, they might have higher maintenance costs due to frequent relocation and operational wear. Stationary crushers have higher upfront costs for site preparation and installation but tend to have lower operating costs over time due to their robust design and higher efficiency in handling large volumes of material.

It's also important to note that many sites can benefit from using both mobile and stationary crushers. Even a project with a stationary crusher can improve efficiency by renting a mobile crusher, particularly for tasks that require flexibility and on-the-spot crushing. This combination allows for optimized workflow and cost management.

Premiertrak 400X portable jaw crusher offers easy track mobility and swift setup. Image credit: powerscreen.

Maintenance Demands

Because of their constant relocation and exposure to diverse environments, mobile crushers may require more frequent maintenance and repairs. For example, the hydraulic hoses, which are essential for operating the crusher&#;s mobile components, may experience increased wear due to the flexing and vibrations caused by transportation and repositioning. Tracks also endure significant stress as they traverse rough or uneven surfaces.
Maintenance for stationary crushers generally focuses on routine upkeep, such as lubrication of bearings and periodic checks on the machine&#;s structure.

At Al Marwan Machinery, we provide a variety of equipment according to your crushing needs. Take a look at our brand-new inventory and let our experts help you make the right choice!

Want more information on Crushing & Screening Equipment? Feel free to contact us.