How to choose between cone crusher and impact crusher?
In the crushing operations of mining, construction and other industries, cone crushers and impact crushers are commonly used equipment, and they have their own characteristics and applicable scenarios.In actual production, how to choose these two crushers correctly is an important issue related to production efficiency, cost control and product quality.The following will compare and analyze these two crushers from many aspects to provide a reference for your choice.
Comparison of working principles
When the cone crusher is working, the rotation of the motor is rotated by the pulley or coupling, the drive shaft and the cone part are forced by the eccentric sleeve to make a fixed pendulum movement, so that the crushing wall of the cone crusher sometimes approaches and sometimes leaves the surface of the rolling mortar wall fixed on the adjustment sleeve, so that the ore is constantly impacted, squeezed and bent in the crushing chamber to achieve ore crushing.
The impact crusher uses a plate hammer on a high-speed rotating rotor to produce a high-speed impact on the material fed into the crushing chamber and crush it, and the broken material is thrown at high speed along the tangent direction to the counterattack plate at the other end of the crushing chamber, it is broken again, and then it bounces from the counterattack plate to the area of action of the plate hammer and is broken again. This process is repeated until the material is broken to the desired particle size and discharged from the lower part of the machine.
It can be seen from the working principle that cone crushers are extrusion crushers and impact crushers are impact crushers, which also determines their subsequent differences in many aspects.
Applicable material differences
Cone crusher is suitable for crushing all kinds of medium-hard and hard ores and rocks, such as iron ore, copper ore, limestone, granite, etc.Due to its extrusion and crushing method, it has a better treatment effect on materials with high hardness and strong abrasive properties, can be effectively broken and equipment wear is relatively controllable.
The impact crusher is suitable for crushing materials of medium hardness and below, such as limestone, coal gangue, gypsum, etc.The impact crushing method enables it to obtain a better particle shape when dealing with brittle materials, but for materials with high hardness, wearing parts such as plate hammers wear out faster, which will increase production costs.
For example, in the crushing operations of limestone mines, if the ore hardness is moderate and the particle shape requirements are not particularly demanding, both crushers can be used; however, if it is quartz stone and other higher hardness ores, cone crushers are more suitable.
Product particle shape and particle size
The products produced by the impact crusher have good particle shape, mostly cubes, uniform particle size, and low content of fine powder and stone powder.This is because its impact crushing method can break the material along the weak surface, thereby obtaining a better particle shape, which is very suitable for construction projects with high requirements for stone particle shape, such as expressways, high-rise buildings, etc.
The particle shape of the product broken by the cone crusher is relatively poor and the content of needle flakes is high, but it can accurately control the particle size of the product by adjusting the size of the discharge port, and it can produce products of different specifications to meet a variety of production needs.In some occasions where the particle shape requirements are not high, but there are strict requirements for the particle size range, such as ore crushing in mine selection plants, cone crushers are more suitable.
Production capacity and efficiency
Generally speaking, the production capacity of cone crushers is large, especially large cone crushers, the output per hour can reach hundreds or even thousands of tons.It can work continuously and stably, and is suitable for large-scale production operations.Moreover, the crushing ratio of the cone crusher is large, the unit energy consumption is relatively low, and it has high production efficiency when processing a large number of materials.
The production capacity of the impact crusher is relatively small, but its crushing efficiency is high, and it can crush the material to a smaller particle size in a shorter period of time.For small-scale production or occasions where production capacity requirements are not particularly high, impact crushers are a good choice.
Equipment investment and operating costs
The equipment price of cone crushers is relatively high, especially some high-performance and large-scale cone crushers, which have a large initial investment cost.However, its wearing parts have a long service life, a relatively long maintenance cycle, and relatively stable operating costs.In the long-term production process, with the use of equipment, its cost advantages will gradually appear.
The equipment price of impact crusher is relatively low, and the initial investment is small.However, due to the rapid wear and tear of its wearing parts (such as plate hammers, counterattack plates, etc.), it needs to be replaced frequently, which will increase the operating cost of the equipment.Moreover, when dealing with materials with higher hardness, the replacement frequency of wearing parts will be higher, and the operating cost will increase accordingly.
Selection suggestion
Production scale
If it is a large-scale mining or large-scale construction project with high requirements for production capacity, a cone crusher is a better choice. It can meet the crushing needs of a large number of materials and ensure the continuity and stability of production.
Material characteristics
For materials with high hardness and strong abrasive properties, cone crushers are preferred; for brittle materials with medium hardness and below, impact crushers can obtain better particle shape and crushing effect.
Product requirements
If the particle shape requirements of the product are high, such as for high-end construction projects, the impact crusher is the first choice; if the particle size control requirements are strict, the cone crusher can better meet the needs.
Cost considerations
If the initial capital is limited and the production scale is small, the impact crusher can be used as a transition equipment; if long-term stable operation and low comprehensive cost are pursued, although the cone crusher has a large initial investment, it has obvious advantages in the later stage.
