How Does crushing equipment Work?

Crushing equipment is essential in mining, aggregate, mineral processing, recycling, and other material handling plants. Specifically, it reduces raw material size, making them closer to the end-product and sellable. The role of crushers in such plants is fundamental, typically being the initial step post material collection.

For the first installment of our Equipment 101 series, we will delve into the essentials of crushing equipment. Kemper's experienced team knows what it takes to turn raw material into a profitable product. Read on to learn more about how crushing equipment fits into material handling and how Kemper can help:

What is Crushing Equipment?

Crushing equipment is machineries designed to reduce material size into smaller fragments. These are usually heavy machines integrated into a material handling system or plant. Rock crushers use significant force to break materials apart.

Crushers primarily use heavy plates or jaws to apply pressure to the material in the chamber. Although some crushers are portable, they are generally built into a full circuit material handling system. At most rock quarries or mineral processing operations, you find conveyors, crushers, and screening machines working together to break down raw material into marketable products.

How Does Crushing Equipment Work?

Most crushing equipment comprises chambers with heavy-duty plates or jaws. Raw material is fed into the crusher, where the plates come together to reduce its size through considerable force and pressure. These plates move both up and down, significantly decreasing material size.

Some plants utilize multiple crushers to size down raw materials efficiently. Heavy-duty crushers generally handle larger pieces initially, whereas smaller crushers break down these pieces further. Jaw crushers, for instance, manage large chunks, preparing them for secondary crushers, which further refine the material before it goes through screening.

How is Crushing Equipment Used?

Crushing equipment is pivotal in various material handling plants, productions, and job types. The type of crusher required depends on the starting material. While most crushers operate similarly, their applications vary significantly. Here are some industries that rely on crushers:

• Mining
• Rock Quarries
• Mineral Processing
• Recycling

The mining and quarrying industry is a significant user of crushing equipment. Raw material blasted from deep underground goes through extensive handling before becoming profitable. This involves moving the material, crushing, and screening it to separate particles. Crushing equipment coordinates with other machines to create the final product, such as gravel for roads or salt for winterizing.

The recycling industry breaks down glass bottles and containers using crushers. Post crushing, the glass is melted and repurposed into new containers, ready for another cycle of use.

What Does Kemper Do?

Kemper's team boasts over 30 years of experience in the material handling sector. Each crusher has a specific role, crucial for creating the desired product. Kemper supplies and installs various types of crushers, including:

Our services extend beyond recommending and installing crushers. We offer consulting, planning, designing full circuit systems, and are a full-service material handling supplier capable of building and repairing entire systems.

In rock, sand, gravel, or mineral processing industries, various types and styles of crushing equipment exist. Your required crushers—jaw, cone, impact, or gyratory—depend on your site, product specifics, and production needs.

Each crusher's construction and abilities dictate its fit within your processing operations. Multiple crushers often operate in primary, secondary, and tertiary stations to accomplish necessary material reduction work, each offering unique strengths and process benefits.

Today's focus is on compression-style jaw crushers, typically in the primary stage. Know that sometimes cone crushers may replace jaw crushers, and we'll touch on their advantages.

What is a Jaw Crusher?

Jaw crushers, sometimes called "rock breakers," are famous for their brute force, making them ideal as primary crushers. They efficiently break large and hard materials into manageable sizes for further reduction. Advantages include:

• Handling various materials with less wear and tear compared to primary impact-style crushers, from hard granite to reclaimed asphalt pavement (RAP).
• Minimizing fine materials and dust output.
• Being more efficient than primary gyratory crushers.

Due to their compact size, jaw crushers are ideal for spaces like underground mining and mobile crushing applications where other primary solutions do not fit.

Types of Jaw Crushers

Jaw crushers, one of the oldest types, have technologically evolved to become more durable and efficient at reducing choking and increasing operational speed. Two primary configurations exist:

Double Toggle – Blake Type or Overhead Pivot Movement

Double toggle movement crushers, named after Eli Whitney Blake, the inventor of the first successful mechanical jaw crusher, crush hard and abrasive rocks. They are known for high energy efficiency and reduced wear and tear due to the overhead pivot design.

Single Toggle – Overhead Eccentric Movement

Single toggle movement crushers were once limited in handling large feed sizes but now, thanks to technological advancements, they work faster. They experience more wear and tear than double toggle crushers, but economical and widely available wear parts keep them highly favored.

How does a Jaw Crusher work?

All jaw crushers compress large rocks, ores, or other materials via a fixed, V-shaped jaw and a movable "swing" jaw. The feed material is pushed against the stationary plate, and the output gap at the bottom of the V determines the crushed product size.

Which are better, Jaw or Cone Crushers?

Jaw crushers are often a smart primary stage choice; however, newer cone crushers are increasingly replacing them for versatility. Both jaw and cone crushers work by compression. Cone crushers, however, offer a more cubical product output similar to impact crushers, making them ideal for secondary and tertiary crushing stations.

Ultimately, the best crusher depends on your production needs and goals.

How can I find the best crushers for my operations?

Crushers are customizable to optimize material extraction, breakdown, and economic transportation to market. The best way to identify the right crushers for your operation is by collaborating with knowledgeable material handling solutions providers like Kemper Equipment. Contact us to learn how a custom-designed crushing circuit or a few new crushers can boost productivity and transform your operations.

Mining, aggregate and mineral processing, recycling, and other material handling plants require size reduction of their raw materials to create sellable end-products. Once collected, these raw materials need processing to break them down.

This is where crushing equipment comes in. Crushers play a crucial role in full circuit material handling plants. They typically serve as the first or second stage post raw material arrival.

For the first edition of our Equipment 101 series, we explore everything about crushing equipment. Kemper's experienced team provides insights on turning raw material into profitable products. Read on to understand how crushing equipment integrates into material handling and how Kemper can assist:

What is Crushing Equipment?

Simply put, crushing equipment reduces material size into smaller pieces. These heavy machines are part of a material handling system or plant, using significant force to impact and break materials.

Crushing equipment typically features heavy plates or jaws to apply pressure to chambered materials. While some crushers are portable, they are mostly components of full circuit material handling systems, found in rock quarries or mineral processing operations. These systems jointly convert raw materials into marketable products.

How Does Crushing Equipment Work?

Heavy-duty plates or jaws form the primary components of most crushing equipment. When raw material enters the crusher, the plates compress it, significantly reducing its size through powerful up and down movements.

Some plants use multiple crushers for optimal size reduction. Initially, heavy-duty crushers manage large pieces, followed by smaller crushers for further refinement. Jaw crushers handle large chunks, breaking them down for secondary crushers, which then further reduce the material before it reaches screening equipment.

How is Crushing Equipment Used?

Crushing equipment begins various material handling processes, production, and jobs. Different jobs demand different types of crushers. Despite their operational similarities, the applications of crushers span numerous industries, including:

• Mining
• Rock Quarries
• Mineral Processing
• Recycling

Mining and quarrying rely heavily on crushing equipment. Raw material, blasted from underground, undergoes extensive processing for profitability. This includes moving the material, crushing, and screening to separate particles. Crushers work alongside other machines to create the final products, like road gravel or winterizing salt.

The recycling sector also employs crushers to break down glass bottles and containers. The crushed glass becomes raw material, melted and repurposed into new containers, ready for another cycle.

What Does Kemper Do?

With over 30 years of experience in the material handling industry, Kemper ensures the right crusher for desired product output. Kemper supplies and installs various crushers, from jaw to cone to impact and more.

More than recommending and installing crushers, Kemper offers consulting, planning, and designing full circuit systems. As a full-service material handling supplier, Kemper can design, build, and repair your entire system.