Top Impact Crusher Manufacturer | Heavy-Duty Crushing Machines-Yude

Our Capabilities

A Jaw Crusher is widely used in various industries to crush different types of materials. Its primary function is to reduce large rocks or ores into smaller, more manageable sizes.

Dolomite

Medium-hard rock used in construction and industrial applications

Used in cement production, road base, and agriculture

Brick & Clay (Recycled)

Crushed for reuse in construction and landscaping applications

Gypsum

Soft and non-abrasive

Used in drywall production, cement additives, and fertilizers

Coal

Brittle and soft material

Crushed for use in power generation and industrial heating

Concrete & Asphalt (Recycled)

Demolition waste from construction projects

Used for road sub-base, aggregates, and new concrete/asphalt production

Limestone

Soft and easy to crush

Used in cement production, road base, and building materials

Impact Crusher Crushing Process

The crushing process within an impact crusher relies on the principle of impact rather than compression.

Process

Material Feeding:

Raw material, typically pre-screened to remove oversized pieces, is fed into the crusher's feed hopper.

A feeder (vibrating feeder, belt feeder, etc.) controls the flow of material into the crushing chamber. A consistent and controlled feed rate is crucial for optimal crusher performance and to prevent overloading.

Process

Rotor and Blow Bar Impact:

The heart of the impact crusher is the rotor, a heavy rotating cylinder fitted with blow bars (also called hammers or impact bars).

The rotor spins at a high speed, propelling the blow bars into the incoming material.

The blow bars are strategically positioned around the rotor's circumference to maximize impact force. They are usually made of wear-resistant materials like high-chrome iron, manganese steel, or ceramic composites.

Process

Primary Impact:

As the material enters the crushing chamber, it is struck by the rapidly rotating blow bars.

This forceful impact shatters the material into smaller pieces. The kinetic energy of the blow bars is transferred to the material, causing it to fracture along its weakest points.

Process

Secondary Impact (Crushing Chamber Walls/Impact Plates):

After the initial impact, the broken material is thrown against the impact plates (also called anvils or breaker plates) lining the crushing chamber.

These impact plates are strategically positioned to create a rebounding effect, causing the material to undergo further crushing and fragmentation as it collides with them.

The angle and adjustability of the impact plates are critical for controlling the product size and shape. Moving the impact plates closer to the rotor results in a finer product. Moving them further away produces a coarser product.

Process

Tertiary Impact (Optional):

Some advanced impact crusher designs incorporate a third stage of impact using a second set of impact plates or an additional rotor/blow bar arrangement. This is more common in secondary or tertiary crushing applications where a finer product is required.

Process

Discharge:

After being crushed through the impact stages, the material falls through the bottom of the crushing chamber.

The size of the discharge opening (gap setting) also influences the final product size. A narrower gap will result in a smaller product size.

Process

Screening (Often Integrated):

The crushed material is often passed through a built-in or separate screening system to separate it into different size fractions.

Oversized material may be recirculated back to the crusher for further processing.

Impact Crusher Working Principle

Components

Rotor: The rotating central component with hammers or blow bars.

Hammers/Blow Bars: The impacting elements attached to the rotor. Hammers are typically used for softer materials, while blow bars are for harder materials.

Impact Plates/Aprons: The stationary plates against which the material is thrown. Adjustable impact plates provide control over the final product size.

Feed Hopper: The entry point for the material to be crushed.

Discharge Chute: The exit point for the crushed material.

Crusher Housing: The outer shell of the crusher, enclosing the working components.

Working Principle

1. Feeding and Initial Impact: Material Input Material (like rock, ore, or concrete) is fed into the crusher's feed hopper. The size of the feed is dependent on the crusher's model and design. Rotor and Hammers/Blow Bars A rapidly rotating rotor, equipped with hammers or blow bars, is the heart of the impact crusher. The rotor spins at a high speed. Primary Impact As the material falls into the crusher, it is struck by the rotating hammers or blow bars. This initial impact is the first stage of size reduction. The high-velocity impact throws the material against the impact plates.

2. Secondary Crushing (Impact Plate Collision): Impact Plates/Aprons The material, propelled by the hammers/blow bars, collides with stationary impact plates or aprons lining the crusher's interior. These plates are strategically positioned to optimize the crushing process. Secondary Impact This collision causes further fracturing and crushing of the material. The material is repeatedly bounced between the hammers/blow bars and the impact plates. Some crushers have adjustable impact plates, allowing for control over the final product size.

3. Tertiary Crushing (Inter-Particle Attrition): Material-on-Material Crushing After multiple impacts with the hammers and impact plates, the material also collides with itself within the crusher. This inter-particle attrition contributes to further size reduction and shaping of the product.

4. Discharge and Screening: Discharge Chute The crushed material falls through the discharge opening at the bottom of the crusher. The size of the opening helps to regulate the maximum size of the output product. Screening (Separate Process) Often, the discharged material is then sent to a separate screening system (vibrating screens) to separate the crushed material into different size fractions. Oversized material might be returned to the crusher for further reduction.

Impact Crusher Features

An impact crusher is a type of crusher that uses high-speed impact force to break down materials. These crushers are widely used in mining, construction, recycling, and other industries due to their efficiency and versatility.

Crushing Mechanism

Operates by using a high-speed rotor with blow bars (hammers) to impact materials. The materials are thrown against impact plates or anvils, where they break apart due to the force of collision.

Versatile Crushing

Suitable for primary, secondary, and tertiary crushing stages. Capable of handling a variety of materials, including: Soft to medium-hard rocks (e.g., limestone, gypsum). Abrasive materials (e.g., granite, basalt) with specialized wear-resistant parts. Recyclable materials like concrete, asphalt, and glass.

Adjustable Output Size

Features adjustable settings to control the gap between the rotor and impact plates (breaker plates), allowing customization of product size. Produces well-shaped, consistent aggregates with minimal fines.

High Crushing Efficiency

Offers a high reduction ratio, often exceeding 10:1, making it ideal for producing fine or medium-sized materials. Efficiently processes materials with large feed sizes.

Design Flexibility

Horizontal Shaft Impact Crushers (HSI): Best for softer materials and recycling applications. Vertical Shaft Impact Crushers (VSI): Ideal for shaping aggregates and producing high-quality sand.

Energy Efficiency

Consumes less power than other crushers for comparable output, reducing operational costs. High-speed rotors enhance efficiency by delivering strong impact force.

Wear-Resistant Components

Blow bars, impact plates, and rotor surfaces are typically made of durable materials such as manganese steel or chrome alloys. Components are replaceable, ensuring extended service life.

Impact Crusher Series

Vertical Impact Crusher Sand Making Machine

$Vertical Impact Crusher (For Refractory Materials)$

Vertical Impact Crusher (For Refractory Materials)

Industry Application

Road Construction

Base Layer Material: Creates high-quality aggregates for road base layers.

Gravel Production: Used in the production of gravel for road surfacing.

Cement Industry

Raw Material Processing: Impact crushers break down materials like limestone, clay, and marl into smaller sizes for cement manufacturing.

Quarrying

Stone Crushing: Effective for crushing non-abrasive to moderately abrasive rocks, including limestone, sandstone, and shale.

Shaping Aggregates: Produces well-shaped, cubical particles, which are ideal for concrete and asphalt production.

Mining Industry

Ore Processing: Suitable for crushing medium-hard and soft ores, such as limestone, gypsum, and phosphate.

Secondary Crushing: Often used after primary crushers to reduce ore to a manageable size for further processing.

Construction and Demolition

Aggregate Production: Commonly used to produce fine aggregates, such as sand and gravel, for construction projects.

Concrete Recycling: Breaks down concrete into smaller pieces for reuse as base material in new construction.

Asphalt Recycling: Crushes asphalt pavement for recycling into road base or new asphalt production.

Jaw Crusher FAQ

Let us bring you better service

How do you maintain an impact crusher?

Regularly inspect and replace worn blow bars and impact plates.
Keep the rotor balanced to avoid vibrations.
Monitor bearing conditions and lubrication.
Ensure proper feed size and avoid overloading.

What factors affect the performance of an impact crusher?

Material Properties: Hardness, abrasiveness, and moisture content.
Feed Size: Crushers work best with materials within their feed size limits.
Rotor Speed: Higher speeds increase impact force but may produce more fines.
Wear Parts: Condition and quality of blow bars and impact plates.

What industries use impact crushers?

Mining: Crushing ores before processing.
Construction: Producing aggregates for concrete and road bases.
Recycling: Breaking down construction and demolition waste.
Cement Industry: Crushing limestone for clinker production.

How does an impact crusher work?

Material enters the crusher through a feed opening.
Rotating blow bars strike the material, propelling it against impact plates or anvils.
The material fractures upon impact and is reduced to the desired size.
The final product is discharged through the bottom of the crusher.

What are the advantages of an impact crusher?

High Reduction Ratios: Capable of producing fine and uniform outputs.
Versatility: Handles a wide range of materials and applications.
Cubic Product Shape: Produces well-shaped aggregates for construction.
Simple Maintenance: Easy access to wear parts for quick replacements.
Cost-Effective: High efficiency with reduced energy consumption.

What materials can impact crushers process?

Impact crushers are versatile and can crush:
Soft to medium-hard materials: Limestone, gypsum, coal.
Hard materials: Granite, basalt (with some models).
Recyclables: Concrete, asphalt, glass, and slag.

What types of impact crushers are there?

There are two main types of impact crushers:
Horizontal Shaft Impact (HSI) Crushers:
Rotor mounted horizontally.
Best for soft to medium-hard materials.
Commonly used for primary and secondary crushing.
Vertical Shaft Impact (VSI) Crushers:
Rotor mounted vertically.
Used for producing high-quality aggregates and sand.
Ideal for tertiary or quaternary crushing.

What is an impact crusher?

An impact crusher is a type of crushing machine that uses high-speed impact force to break down materials. It features a rotor with blow bars that hurls material against impact plates or anvils to achieve size reduction.

Yude

Mechanical

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86-139-3993-0123

sales@yd-crusher.com

Luoyang Luoxin Industrial Park, Henan,China

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