Aggregate stone crushers are machines used in mining, quarrying, and construction industries to break down and reduce the size of large rocks, stones, and other materials into smaller and more manageable pieces. These crushers play a vital role in producing high-quality aggregates used in various applications such as road construction, concrete production, and building materials.
Aggregate stone crushers typically operate in three stages: primary crushing, secondary crushing, and tertiary crushing. Each stage involves different types of crushers and processes to achieve the desired size and shape of the final product. Let’s explore these stages in more detail:
Primary Crushing:
The primary crushing stage involves the initial reduction of the raw material obtained from the quarry. Large rocks and stones are fed into the crusher, which uses a compression force to break them down into smaller pieces. Common types of crushers used for primary crushing include jaw crushers, gyratory crushers, and impact crushers.
Jaw Crushers: These crushers have a fixed jaw and a movable jaw. The material is fed between the jaws, and as the movable jaw moves, it compresses the rock against the fixed jaw, breaking it into smaller pieces.
Gyratory Crushers: Gyratory crushers consist of a conical-shaped outer shell and a central gyrating mantle. Material is fed through the top opening and is crushed as it moves down between the mantle and shell.
Impact Crushers: Impact crushers use the principle of impact and collision to break down the material. The material is fed into a chamber where it is rapidly accelerated and strikes a stationary object, resulting in fragmentation.
Secondary Crushing:
The secondary crushing stage involves further reducing the size of the material obtained from the primary crusher. The aim is to produce aggregate with a consistent size distribution. Common types of crushers used for secondary crushing include cone crushers and impact crushers.
Cone Crushers: Cone crushers operate by squeezing the material between an eccentrically rotating mantle and a concave. As the mantle moves, it compresses the material against the concave, breaking it down further.
Impact Crushers: In the secondary stage, impact crushers can be used again to further refine the shape and size of the aggregate. They operate similarly to primary impact crushers but are designed for smaller feed sizes and higher reduction ratios.
Tertiary Crushing:
The tertiary crushing stage is optional and is used to further reduce the size of the aggregate into finer particles. This stage is typically employed when the final product requires a specific shape or when additional fine aggregates are needed. Common types of crushers used for tertiary crushing include vertical shaft impact (VSI) crushers and cone crushers.
VSI Crushers: VSI crushers use a high-speed rotor and anvils for impact crushing. They are particularly effective in producing cubical-shaped aggregates and are often used in the production of manufactured sand.
Cone Crushers: Cone crushers can also be used for tertiary crushing. They provide excellent reduction and shape characteristics and are well-suited for producing high-quality aggregates.
In addition to these primary, secondary, and tertiary crushers, aggregate stone crushing plants may also include other equipment such as vibrating screens, conveyors, and feeders to handle and process the crushed materials efficiently.