Rock crushers are machines used to crush rocks and reduce their size in aggregates production. These machines can be categorized in many stages of duties. Rock crushing machines are available for primary, secondary, and tertiary crushing stages. Quaternary crushing is a forth but very rare stage of rock crushing.
Most rock crushers contain a hopper at the top i.e. a container that holds the rock above the crusher. Such types of crushers use gravity for feeding. Alternately, some rock crushers use a belt drive to move the rock into the crusher.
After crushing the rocks into the small pieces enough to fit through the hole, it exits the crushed rocks onto a conveyor belt. In some cases, these crushed rocks pass through the second and third phases of crushing. This article explains different types of rock crushers and their most important wear parts. Let’s begin with the brief introduction of rock crushing machines:
Different Types of Rock Crushing Machines
All rock crushers apply pressure gradually to the objects that take the load as simple beams or short columns. There are two types of general mechanism used for crushing as follows:
Reciprocating Rock Crushing: In this approach, crushing surfaces of reciprocating rock crusher approach and withdraw from each other. These types of crushers include Jaw, gyratory, and cone crushers.
Continuous Rock Crushing: In this case, there is a continuous method of the crushing surfaces to a considerably static predetermined minimum spacing. This type of crushers include rolls and single-roll crushers. Roller mills and impact crushers also fall in this category.
In simple words, there are major types of rock crushers in the market as follows:
- Jaw crusher: It is a primary crushing machine.
- Roller crusher: This is another renowned crusher available for primary and secondary crushing.
- Gyratory crusher: Gyratory crushers are available for primary crushing.
- Impact crusher: This machine is used for both primary and secondary purposes.
- Cone Crusher: It is another most popular secondary crushing machine.
Rock Crusher Wear Parts
So far, you have learned different types of rock crushing machines. Let’s dive deeper and explore the main spare parts or wear parts of the crushing machines:
Crusher wear parts are used for processing all rocks ranges from surface to underground operations. These parts are available for mining industries, cement, and aggregates. Wear parts not only boosts the performance of the machine but also decrease the cost of operation.
The most common spare parts of jaw stone crushers are liners, fixed jaw plates, and protection plates. These parts are made of manganese steel that makes the spare parts very reliable. In addition to this, high-quality parts make the machine long-lasting. The majority of the crushing wearing parts are made of Mn14, Mn18, Mn14Cr2, and Mn22Cr2.
Another remarkable material used in the formation of spare parts is titanium carbide. The life span of titanium carbide made components is 2 to 3 times longer than those parts made with only manganese steel. Here are the most common rock crusher wear parts:
- Fixed Jaw plates
- Motor seals
- Protection plates
- Movable jaw plates
Manganese is the most common material for making cone crusher wear parts. Because manganese provides mounting possibilities, reliability, and shear strength to the wear parts. It also enhances the life of all components. Mantles, bowl liners, and concaves are made of Mn14, Mn18, and Mn22. Similarly, standard manganese is used in the construction of feed cones.
Therefore, wear parts that are made of manganese are very effective and suitable for all environments. These parts are designed to crush the hardest rocks in the harshest environment. So they can perform well in stationary to mobile crushing environments. Below are some common types of rock crusher wear parts:
- Concave ring
- Dust seal
- Bowl liners
- Cone crusher gears
- Feed cones
- Rock Roller Crusher Wear Parts
Roller crusher is another most popular machines for stone crushing. It comes with a set of two large metal rollers that rotate in opposite directions of each other. Put the rocks between the two rollers for crushing purposes. The main material used for making its wear parts is manganese. Here are a few important wear parts of roll crusher:
Horizontal impact crushers or simply rock impact crushers are designed to work in the toughest environment range from ground to underground environments. Wear parts don’t only boost the performance but also last for a long period.
Martensitic alloy steel and high chrome steel is used as a construction material of standard wear parts of rock impact crusher wear parts. Chrome white iron, manganese steel, and a mixture of other materials are also used in the wear parts. In most cases, high chrome steel is used for impact plates and side plates construction.
You must use high-quality material for wear parts. Because you have to use it for aggregates, cement, and mining industries, etc. These long-lasting components increase the life of crushing machines which reduce the cost of crusher due to its long-lasting parts. Here are some primary rock crusher wear parts:
- Blow bars
- Side plates
- Impact plates
Gyratory is one of the robust rock and ore crushing machines. It performs primary crushing so its wear parts should be very strong and of high-quality. Its major purpose is to reduce the size of giant rock for further stages of crushing.
Manganese steel that includes Mn14, Mn18, and Mn22 is the standard material for gyratory mantles. The most appropriate material for concave segments is high chrome and manganese steel. However, some manufactures prefer low alloy steel for crusher wear parts production. Some remarkable wear parts are as follows:
- Spider cap
- Bottom shell side liners
- Rim liners
- Concave segments
- Arm liners
Manganese is a primary and basic building block of almost all types of crusher wear parts. It is a cost-effective but very efficient material for wear parts. Tungsten carbide is another useful material for wear parts. So always use high-quality components for reliable and productive stone crushing.