Selecting a crusher for your quarry plant involves the consideration of a range of important factors, ensuring your investment will lead to increased efficiency, productivity, and safety.

There are several key things you need to weigh up when selecting a fixed or mobile crusher, or crushers, for your new or established crushing operation.

“Some people familiar with the methods for selecting crushing equipment believe you can select a crusher purely based on calculations,” says Garth Taylor, MIMICO’s Material Processing Business Manager.

“However, theoretical assumptions should always be balanced by practical experience with different material, as well as with the operational, maintenance and economic aspects of the various options.”

• What will I be feeding my crusher?
• What product do I want to obtain?
• What are the strengths of each crusher type?
• What are my power requirements?
• What is my total cost of ownership?

1. What will I be feeding my crusher?

When selecting a crusher, understanding the characteristics of the material you intend to crush plays a significant role in crusher selection.

Materials can vary widely in terms of hardness, abrasiveness, moisture content, and the size and shape of the particles.

“Harder materials, like granite or basalt, are more challenging to crush and require a more robust machine,” says Taylor. “On the other hand, softer materials, like limestone, are easier to crush but can also have variable abrasion, potentially increasing wear on the crusher.”

Moisture content is another vital consideration. High moisture levels can cause clogging, reduce crushing efficiency and produce elevated wear. Additionally, the material’s density and the presence of contaminants like soil or clay can affect the crushing process.

The size of the feed material plays a significant role in crusher selection.

“Large, bulky materials require crushers with large feed openings and the capacity to handle high throughputs,” explains Taylor. “The nature of the feed material, whether it’s blasted rock, gravel, or recycled concrete, will also influence the choice of crusher.”

Blasted rock typically has a wide range of sizes, requiring a crusher that can handle oversized material while producing a consistent output size. Gravel or other alluvial deposits might need a different approach, possibly involving a combination of crushing and screening to achieve the desired product.

2. What product do I want to obtain?

Your desired end-product is a crucial factor in selecting the right crusher. The target product size and shape will dictate the type of crusher, and the crushing stages needed.

As an example, if the goal is to produce a fine aggregate for concrete, a vertical shaft impact (VSI) crusher might be the best choice, as it produces high-quality, cubical particles. On the other hand, if a more substantial, coarse product is needed for road construction, a jaw crusher followed by a cone crusher could be more appropriate.

Consideration of the desired product’s size distribution, shape, and quality is essential in making the right choice.

3. What are the strengths of each crusher type?

All crushers can be classified into two main types. Compressive crushers compress the material until it breaks, while impact crushers use the principle of quick impacts to crush the material.

“Jaw and cone crushers, along with gyratory and roller crushers, operate according to the compression principle, while impactors and hammer mills use the impact principle,” says Taylor.

The different types of crushers offer distinct features and benefits:

• Jaw crushers are known for their simple structure, high crushing ratio, and reliable performance, making them suitable for primary crushing of hard and abrasive materials.
• Cone crushers are ideal for secondary and tertiary crushing stages, providing high productivity and a high-quality final product.
• Impact crushers come in two types:
  • Horizontal shaft impactors (HSIs) offer high reduction ratios and are effective for producing coarse and fine aggregates.
  • Vertical shaft impactors (VSIs) offer excellent production of cubical particles and manufactured sand.
• Mobile crushers provide flexibility, allowing you to move the crushing operation closer to the source material, reducing transportation costs.

Each type has its advantages and limitations, making it essential to match the crusher to the specific needs of the operation.

4. What are my power requirements?

Power requirements are a critical consideration in crusher selection. Crushers are energy-intensive machines, and their power consumption can significantly impact operating costs. The power required depends on the crusher type, material characteristics, and the desired production capacity.

For example, jaw crushers typically require less power than impact crushers for the same material and capacity. Energy efficiency is an essential factor, as it directly affects the operational cost and environmental footprint of the crushing operation.

“A jaw crusher requires less power than an impact crusher for the same material and capacity,” says Taylor. “But, if we take this a step further and look at the energy required to produce a ton of product, the impactor may be more energy efficient, depending on product size required.”

Selecting a crusher with optimal power requirements that match the available power supply is vital for efficient and sustainable operation.

5. What is my total cost of ownership?

The total cost of ownership of a crusher includes not just the initial purchase price but also operating costs, maintenance expenses, and the cost of downtime. While a lower upfront cost might seem attractive, it could lead to higher operational costs if the crusher is inefficient or prone to frequent breakdowns.

It’s essential to consider the long-term costs associated with power consumption, wear parts, maintenance, and potential downtime. Investing in a high-quality crusher that offers reliability, energy efficiency, and durability can reduce the total cost of ownership, providing better value over the crusher’s lifetime.

“Additionally, the availability of spare parts and the manufacturer’s support network are important factors in ensuring minimal downtime and optimal performance,” suggests Taylor.

MIMICO holds an extensive selection of OEM parts for all the equipment brands the company works with, and are also specialist in indent parts supply for a range of makes and models.

Wear cost is a significant factor in the total cost of ownership of a crusher. Crushers operate in harsh environments and are subjected to constant wear and tear. The type of material being crushed, its abrasiveness, and the crusher’s design all have an impact on wear cost.

For instance, harder materials cause more wear on crusher parts, increasing maintenance frequency and replacement costs.

Advanced crusher designs and wear-resistant materials can help reduce wear costs, extending the life of the crusher and its components. Regular maintenance and using high-quality wear parts are essential strategies for minimising wear costs and ensuring the crusher operates efficiently over its lifespan.

Process simulation can help

The basic objective of crushing process planning is to be able to define a process that fulfils the end-product quality and quantity requirements reliably and economically. Software, including Bruno, a Metso tool available from MIMICO, will help inform this.

Bruno is an easy-to-use piece of software used for planning and simulating the crushing process. “With Bruno, you can quickly explore various machine combinations for certain applications or find out whether the existing machines are suitable for other applications,” says Taylor.

The core knowledge in Bruno is reliable modelling of unit machine based on extensive field test data from all types of crushers in various applications.

Do you want to know more?

For a more in-depth exploration of crusher selection and the latest information, referring to the Metso Crushing and Screening Handbook is highly recommended. This comprehensive guide offers detailed insights into crusher selection, operation, and maintenance, helping ensure the best possible outcomes for your crushing plant.

MIMICO is the New Zealand distributor of several world class material processing equipment brands. These include Metso, IMS, MDS, McCloskey Environmental, and Superior, which each offer a unique set of capabilities to meet the diverse needs of the material processing industry.