Powerful Jaw Crusher | Heavy-Duty Crushing Solutions-Yude

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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.

Metallurgical Slag Processing

Steel Slag & Iron Slag: Used in cement and construction industries

Chemical Industry

Dolomite & Calcite: Used in fertilizers and chemical production

Phosphate Rock: Processed for fertilizer manufacturing

Recycling Industry

Glass: Crushed for recycling applications

Slag: Industrial byproducts from steel production

Ceramics: Broken tiles and sanitary wares for reuse

Aggregates and Sand Production

Limestone: For cement and road base materials

Gravel: Used in concrete and road construction

Sandstone: Processed for construction sand

Construction and Demolition Waste

Concrete: Used for recycling demolished structures

Asphalt: Crushed for reuse in road construction

Bricks: Recycled for construction materials

Mining and Metallurgy

Hard Rocks: Granite, basalt, quartz, and gneiss

Ores: Iron ore, copper ore, gold ore, silver ore

Coal: Used in coal mining and processing

Jaw Crusher Crushing Process

The crushing process in a jaw crusher involves a series of steps where the material is gradually broken down into smaller pieces through compression and mechanical force.

Process

Material Feeding

Raw materials (e.g., rocks, ores, concrete) are fed into the crushing chamber through a hopper.

A grizzly feeder may be used to pre-screen fines and regulate the feed rate.

Process

Initial Compression & Crushing

The moving jaw (attached to the eccentric shaft) moves toward the fixed jaw.

This action traps the material between the two jaws, applying high compressive force.

Large materials begin to fracture due to the pressure exerted.

Process

Progressive Size Reduction

As the jaw moves back and forth, the material is crushed multiple times.

Fractures propagate, reducing material size gradually.

The motion of the moving jaw creates a wave-like crushing action that ensures continuous breaking.

Process

Discharge of Crushed Material

The crushed particles move downward due to gravity.

When the material becomes small enough, it exits through the discharge opening at the bottom.

The size of the final output can be adjusted by changing the jaw gap (discharge setting).

Process

Recirculation (If Needed)

If oversized particles remain, they may be recirculated back into the jaw crusher for further crushing.

This ensures uniform particle size before sending materials for the next processing stage (e.g., secondary crushing, screening, or grinding).

Jaw Crusher Working Principle

Components

Frame: The main structure that supports all the components.

Fixed Jaw Plate: A stationary jaw plate mounted on the frame.

Moving (Swing) Jaw Plate: A jaw plate that moves back and forth towards the fixed jaw. This is typically mounted on a pitman.

Pitman: A connecting rod that transmits the force from the eccentric shaft to the moving jaw.

Eccentric Shaft (or Main Shaft): A rotating shaft with an offset (eccentric) section that drives the pitman. Rotation converts into a reciprocating motion.

Toggle Plate(s): A plate or plates used to transfer motion from the pitman to the swing jaw, creating the crushing action. Also acts as a safety overload component.

Flywheels: Heavy wheels mounted on the eccentric shaft to store energy and provide smooth operation. They also help overcome the high force required during crushing.

Adjustment Mechanism: A system to adjust the gap between the jaw plates, controlling the output size of the crushed material. This might involve shims, wedges, or hydraulic systems.

Hopper: An area, usually metal, that funnels material into the crusher's maw.

Working Principle

Feeding: Material (rocks, ore, etc.) is fed into the crusher from the top, usually through a hopper.

Eccentric Shaft Rotation: The motor (usually electric) drives the eccentric shaft to rotate.

Pitman Movement: The eccentric rotation causes the pitman to move up and down or back and forth (depending on the crusher design).

Moving Jaw Action: The pitman's motion is transferred to the moving jaw plate through the toggle plate(s). This causes the moving jaw to swing towards the fixed jaw.

Crushing: As the moving jaw swings towards the fixed jaw, the material between the jaws is subjected to immense compressive force. This force exceeds the material's compressive strength, causing it to fracture and break into smaller pieces.

Discharge: The moving jaw retracts, creating a larger gap at the bottom of the crushing chamber. The crushed material then falls downwards due to gravity and is discharged from the bottom of the crusher.

Continuous Cycle: The cycle repeats continuously as the eccentric shaft continues to rotate, resulting in continuous crushing.

Jaw Crusher Features

The features of a jaw crusher depend on its design, operational parameters, and material properties.

High Crushing Ratio

Jaw crushers offer a significant reduction ratio, meaning they can break down large materials into smaller, more manageable sizes in one operation.

Versatility

Suitable for crushing a wide range of materials, including hard, abrasive, and brittle materials like granite, basalt, and quartz, as well as softer materials like limestone and recycled concrete.

Energy Efficiency

Designed to provide efficient crushing with minimal energy consumption, contributing to cost savings during operations.

Simple Structure and Easy Maintenance

Jaw crushers are relatively simple in design and have fewer parts than other crushing machines, so they are easy to maintain and repair and wear parts are simple to replace.

High Throughput

Capable of handling large volumes of material due to its large feed opening and high capacity, depending on the model and material properties.

Adjustable Discharge Size

The discharge opening can be adjusted to achieve the desired product size, offering flexibility for different applications.

Durability

Constructed with robust materials to handle high pressure and wear, ensuring a long service life even under heavy-duty conditions.

Consistent Performance

Delivers a uniform product size with minimal fines, improving downstream processing efficiency.

Reliable Safety Mechanisms

Features like toggle plates act as safety devices to prevent damage to the crusher in case of uncrushable material entering the chamber.

Compact Design

Many models have a relatively compact footprint, making them suitable for operations with limited space.

Noise and Vibration

Although jaw crushers produce some noise and vibration, newer models are often equipped with damping systems to reduce these effects, enhancing operational comfort.

Jaw Crusher Series

CS Series Jaw Crusher

CS series jaw crusher is a new type of jaw crusher that our company has introduced internationally leading jaw crushing technology, adopted the jaw crushing design concepts and technologies accumulated by our company for decades, and optimized in terms of structure, material selection, process, equipment, etc. It has a unique structure and superior performance.

Industry Application

Laboratory and Research

Material Testing: Jaw crushers are often used in laboratories for small-scale crushing and analysis of geological samples or testing new material formulations.

Chemical Industry

Size Reduction: Employed to crush materials required in chemical production, such as limestone for cement manufacturing or other raw inputs.

Metallurgical Industry

Material Preparation: Used in metallurgical plants for crushing raw materials like coal, coke, and other inputs for furnaces.

Construction and Demolition

Aggregate Production: Jaw crushers are employed to produce construction aggregates such as gravel, sand, and crushed stone used in concrete and road bases.

Recycling of Construction Waste: They crush materials like concrete, bricks, and asphalt for reuse in new construction projects.

Mining and Mineral Processing

Primary Crushing: Jaw crushers are used as the first stage in the crushing process to reduce large rocks extracted from mines or quarries into manageable sizes.

Ore Processing: They help crush ores like gold, iron, copper, and other minerals before further processing in grinding mills or flotation plants.

Jaw Crusher FAQ

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What are the main components of a jaw crusher?

Fixed jaw: Stays stationary during operation.
Moving jaw: Moves to crush materials.
Pitman: Connects the moving jaw to the eccentric shaft.
Eccentric shaft: Drives the motion of the moving jaw.
Toggle plates: Transmit force and act as safety devices.
Flywheel: Maintains consistent motion and reduces energy consumption.
Discharge opening: The gap through which crushed material exits.

What materials can a jaw crusher process?

Jaw crushers can handle a variety of materials, including:
Hard rocks (granite, basalt)
Ore
Recycled materials (concrete, asphalt)
Gravel and sand
Soft stones (limestone, gypsum)

What factors affect jaw crusher performance?

Material hardness: Harder materials require more force to crush.
Feed size: Oversized material can reduce efficiency.
Crusher settings: Proper adjustment of the discharge opening and speed is crucial.
Maintenance: Worn parts reduce performance.
Feed rate: A consistent feed improves efficiency.

What are the types of jaw crushers?

Single-toggle jaw crushers: Feature a single toggle plate and a more compact design.
Double-toggle jaw crushers: Use two toggle plates, offering more crushing force but requiring more maintenance.
Universal jaw crushers: Have adjustable discharge settings.

What is a jaw crusher?

A jaw crusher is a type of machinery used in mining and construction to crush large rocks into smaller, more manageable pieces. It uses compressive force to break down materials and is commonly used in primary crushing stages.

How do you adjust the size of the discharge opening?

The discharge opening is adjusted using shims or hydraulic systems. Smaller gaps produce finer output, while larger gaps allow for coarser material.

How does a jaw crusher work?

A jaw crusher has two jaws: one fixed and one that moves back and forth. Material is fed into the top of the machine, and the moving jaw compresses it against the fixed jaw, breaking it into smaller pieces. The crushed material exits through a gap at the bottom.

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