Crusher

Crusher is a machine designed to reduce

large solid material objects into a smaller
volume, or smaller pieces.
Crushers may be used to reduce the size,
or change the form, of waste materials so
they can be more easily disposed of or
recycled, or to reduce the size of a solid
mix of raw materials so that pieces of
different composition can be differentiated.
 Crushing devices hold material between
two parallel solid surfaces, and apply
sufficient force to bring the surfaces
together to generate enough energy
within the material being crushed so that
its molecules separate from (fracturing),
or change alignment in relation to
(deformation), each other.
 The earliest crushers were hand-held
stones, where the weight of the stone
provided a boost to muscle power, used
against a stone anvil.
Production of crushed stone aggregates
involves 1.Quarry operations 2.Reduction
operations.
The quarry operations are
 Drilling

 Blasting

 Loading

 Transporting
The reduction operations are
 Crushing

 Screening

 Handling

 Storing

Proper coordination between quarry

operation and crushing operations should
be employed
Crushers may be classified by stage of crushing.
Primary crusher –Which receive the stone directly
from the quarry and produces first reduction in
size.
Secondary crusher – Output of primary crusher is
fed to a secondary crusher which further
reduces the size.
Tertiary and others –Some stones may pass
through third or fourth crusher
The commonly used crushers are
1.Primary crusher –Jaw crusher and
Gyratory crusher
2.Secondary crusher –Cone crusher and Roll
crusher
3.Tertiary crusher – Rod mill and Ball mill
 If it is a single process, excessive fines will
be generated and normally there is a
limited market for fines.
 As stone passes through the crusher, the
reduction in size can be expressed as the
reduction ratio, ie the ratio of the crusher
feed size to the product size.
 Crushing equipment selection

 The kind of stone to be crushed

 The required capacity of the plant
 The maximum size of the feed stones
 The method of feeding the crusher
 The required size ranges of the product
 By compaction method
Jaw crusher
 A jaw or toggle crusher consists of a set of
vertical jaws, one jaw being fixed and the
other being moved back and forth .
 The jaws are farther apart at the top than
at the bottom, forming a tapered chute so
that the material is crushed progressively
smaller and smaller as it travels downward
until it is small enough to escape from the
bottom opening.
 The movement of the jaw can be quite
small, since complete crushing is not
performed in one stroke.
 The inertia required to crush the material
is provided by a weighted flywheel that
moves a shaft creating an eccentric
motion that causes the closing of the gap.
Single Toggle
 Double Toggle
 The Blake type is a double –toggle jaw
crusher
 The movable jaw is suspended from the
shaft
 Rotating an eccentric shaft actuates the
two toggles and these produce the
crushing action.
Double toggle
 Size of Jaw and Roll crusher
product
 The figure below represents the percent of
material passing or retained on screens having
the size openings indicated.
 To read the chart select the vertical line
corresponding to the crusher setting.
 Then move down this line to the number that
indicates the size of the screen opening.
 From the size of the screen opening proceed
horizontally to the left to determine the percent
of material passing through the screen or to the
right to determine the percent of material
retained on the screen.
 Q .1 A jaw crusher with a closed
setting of 3 inches is fed at the rate
of 50 tons/hr. Determine the amount
of stone produced in tons per hour
within the following size ranges; in
excess of 2 inch, between 2 and 1
inch, between 1 and ¼ inch, and less
than ¼ inch.
 The amount retained on a 2 inch screen is
42% of 50,which is 21 tons per hr. The
amount in each of the size ranges is
determined as
Size Percent Percent in Total Amount
range(in) passing size range output produced in
screens of size range
crusher (tph)
(tph)

Over 2 100-58 42 50 21.0

2-1 58-33 25 50 12.5

1–¼ 33-11 22 50 11.0

¼-0 11- 0 11 50 5.5

Total 100% 50.0

 Cone crusher
 Used as secondary crusher
 Capable of producing large quantities of
uniformly fine crushed stone
 The conical head on the stone crusher is
usually made of manganese steel
 The maximum diameter of the crusher
head can be used to designate the size of
the cone crusher.
A cone crusher differs from a gyratory
crusher in these aspects
 It has a shorter cone

 It has a smaller receiving opening

 It rotates at a higher speed

 It produces a more uniformly sized stone

Reduction ratio of the major type of crushers

Sl No. Crusher type Reduction ratio range

1 Jaw 4:1 to 9:1

2 Gyratory 3:1 to 10:1

3 Cone 4:1 to 6:1

4 Impact 15:1 to 20:1