Core Functions and Value of Crushers in the Conveying Equipment Industry
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In the conveying equipment industry, a crusher is not a direct “conveying device,” but rather a core pre-processing device for materials. Its core function is to crush large, irregularly shaped materials (such as ores, coal, and construction waste) that are generated during mining and processing into sizes that meet the feed requirements, conveying efficiency, and end-process requirements (such as ore dressing, pulverization, and construction aggregates) of subsequent conveying equipment (belt conveyors, screw conveyors, bucket elevators, etc.). It is a key link in ensuring the stable operation of the conveying system and improving the overall production line efficiency.
I. Core Functions and Value of Crushers in the Conveying Equipment Industry
• Adaptation to Conveying Equipment: It solves the problem of large pieces of material (such as ores with a diameter of over 1 meter) that cannot be directly fed into the inlet of the conveyor, preventing blockages and overloading shutdowns of the conveyor.
• Enhancing Conveying Efficiency: After crushing, the material has a more uniform particle size, which can reduce the “bridging” and “uneven loading” phenomena inside the conveyor, thereby increasing the stability of the conveying capacity (for example, after coal is crushed, the conveying efficiency of the belt conveyor can be increased by 15% to 30%).
• Protecting Downstream Equipment: It prevents large, hard materials (such as metal impurities and hard rocks) from entering subsequent fine crushers and grinding machines, reducing equipment wear and maintenance costs.
• Meeting End-Process Requirements: Based on the downstream processes (such as the need for 5-20mm aggregates in concrete mixing and ≤50mm particles in coal-fired power plants), the final particle size of the material can be controlled through crushing to ensure the quality of the end product.
II. Common Types of Crushers and Their Characteristics in the Conveying Equipment Industry
Different materials (with varying hardness, moisture, and viscosity) and conveying scenarios require crushers with different principles. The following are the three most common types of crushers and their compatibility with conveying systems:
Crusher Type | Core Working Principle | Suitable Material Characteristics | Advantages and Limitations |
PE serial Jaw Crusher | Simulates “jaw biting”: The fixed jaw plate and the movable jaw plate perform periodic reciprocating movements to crush large pieces of material by compression and shearing for coarse crushing. | High hardness (compressive strength ≤320 MPa), large-sized materials (feed size ≤1500 mm), such as granite, iron ore, and basalt. | • Advantages: Simple structure, low failure rate, high processing capacity. • Limitations: Coarser output particle size (generally 100-300 mm), not suitable for fine crushing. |
PCH serial Ring hammer crusher | “Layered Compression Crushing”: The movable cone rotates eccentrically inside the fixed cone. The material is crushed through the compressive and grinding actions between the two conical surfaces, which is suitable for medium and fine crushing. | Medium to high hardness materials (such as iron ore and copper ore) that require precise control of particle size (output 5-50 mm). | • Advantages: Good particle shape, uniform particle size, long service life of wear parts. • Limitations: Not suitable for materials with moisture content > 8% (prone to adhesion and blockage). |
Toothed crusher | “Toothed Plate Shearing + Impact Shredding”: The high-speed rotating knife shaft drives multiple sets of toothed plates (or knife discs) to rotate. Through the shearing action of the toothed plate edges, high-speed impact, and the tearing action between adjacent toothed plates, the material is crushed to the target particle size. | 1.Hardness: Medium to low hardness (compressive strength ≤150 MPa), such as coal gangue, shale, plastic, and rubber. 2.Form: Brittle materials (such as ceramic fragments), fibrous materials (such as straw, waste wood, bagasse), and plastic materials (such as waste plastic and rubber blocks). 3. Feed Requirements: Feed size ≤300 mm, moisture content ≤10% (to avoid adhesion to the toothed plates causing blockages). | Advantages: 1. Excellent crushing effect on fibrous and plastic materials (effectively tears fibers and cuts plastic materials, preventing “clumping”). 2. Adjustable output particle size (by adjusting the gap between toothed plates, generally controllable within 5-50 mm). 3. Compact structure, small footprint, suitable for medium and small production lines. 4. Wide adaptability to material forms (can handle brittle, fibrous, and plastic materials). Limitations: 1.When processing high-hardness materials (such as granite and iron ore), the toothed plate edges are prone to chipping and rapid wear, leading to high maintenance costs. 2.Relatively low single-machine processing capacity (usually ≤50 t/h), not suitable for large-scale industrial crushing applications. 3. If the material contains metal impurities (such as nails), it can easily jam the toothed plates or damage the knife shaft, requiring prior impurity removal. 4. Toothed plates need to be regularly disassembled and replaced, which requires a high level of maintenance skill. |
Crusher,Crushers in the Conveying Equipment Industry,Jaw Crusher,Ring hammer crusher,Toothed crusher
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