Industrial Crushers : Working, Types and Applications Explained

Industrial crushers play a crucial role in chemical manufacturing companies by reducing the size of various materials for further processing or disposal. These crushers are designed to handle a wide range of materials, including chemicals, minerals, ores, and other bulk solids. Depending on the specific requirements of the chemical manufacturing company, different types of crushers may be used.

Industrial Crushers Introduction - Mechanical Operations

Definition of Industrial Crushers

Definition: An industrial crusher can be formally defined as a machine or device designed to reduce the size or change the form of materials by applying mechanical force. It is typically used in various industries, including chemical manufacturing, mining, construction, and recycling, to process raw materials or waste materials for further use or disposal.

Working of Industrial Crushers

Industrial crushers employ various crushing mechanisms to break down materials into smaller particles. The choice of crushing mechanism depends on the type of material, desired product size, and the characteristics of the industrial crusher.

Types of Crushing Mechanisms

Here are some common types of crushing mechanisms used in industrial crushers:

Compression: Compression is the primary crushing mechanism used in jaw crushers, gyratory crushers, and cone crushers. In this mechanism, the material is squeezed or compressed between two surfaces, typically a fixed jaw and a movable jaw or a mantle and a concave. Compression crushing is suitable for hard and brittle materials, such as rocks and minerals.
Impact: Impact crushing involves the application of a high-speed impact force to break down materials. Industrial crushers such as impact crushers and hammer mills use this mechanism. Impact crushers utilize the impact force generated by a rotating rotor and hammers or blow bars that strike the material. This mechanism is effective for crushing both hard and soft materials.
Shear: Shear crushing is commonly used in industrial crushers such as double roll crushers and cage mills. In this mechanism, the material is subjected to a combination of compression and shear forces. The crushing surfaces move past each other with a relative motion, causing the material to be sheared or torn apart. Shear crushing is suitable for fibrous or ductile materials.
Attrition: Attrition crushing involves the rubbing or wearing away of the material through frictional forces. It is commonly used in crushers such as impact mills and rotary crushers. The material is fed into the crusher, and the rotating hammers or blades cause the material to collide and wear down through attrition. Attrition crushing is effective for reducing soft or friable materials.
Torsion: Torsion crushing is a less common mechanism used in certain specialized crushers. It involves applying torsional or twisting forces to break down the material. This mechanism is typically used for materials susceptible to cracking or splitting when subjected to compression or impact forces.

It's important to note that some industrial crushers may combine multiple crushing mechanisms or employ additional mechanisms such as cutting, grinding, or pulverizing, depending on the specific application and the desired final product.

Types of Industrial Crushing Equipment

There are several types of industrial crushers used in various industries to reduce the size of materials and facilitate processing. Here are some common types of industrial crushers:

Jaw Crushers: Jaw crushers are primary crushers designed to handle large feed sizes. They use a stationary jaw plate and a moving jaw plate to compress and crush the material. Jaw crushers are versatile and can handle various materials, including rocks, ores, and minerals.
Impact Crushers: Impact crushers utilize the impact force to crush materials. They have a rotor with rotating hammers or blow bars that strike the material and cause it to break. Impact crushers are commonly used for secondary or tertiary crushing of materials such as limestone, concrete, and asphalt.
Cone Crushers: Cone crushers are used for crushing materials by squeezing them between a mantle and a concave. They are suitable for crushing hard and abrasive materials, and they produce a more uniform product compared to jaw or impact crushers. Cone crushers are often used in the mining and aggregate industries.
Gyratory Crushers: Gyratory crushers consist of a conical-shaped main shaft with a mantle positioned on top. The material is fed into the crusher and is crushed between the cover and the concave. Gyratory crushers are primarily used in the mining industry for heavy-duty applications.
Roll Crushers: Roll crushers are designed to crush materials between two cylindrical rolls. The rolls rotate inward and crush the material against a predetermined breaking plate or grinding surface. Roll crushers are used for reducing the size of coal, limestone, clay, and other friable materials.
Hammer Mills: Hammer mills are high-speed rotor impact crushers that utilize hammers or swinging bars to impact the material and break it into smaller pieces. They are commonly used in the agricultural, mining, and chemical industries for size reduction and grinding of various materials.
Ball Mills: While not typically referred to as crushers, ball mills are commonly used in the mining and mineral processing industry for size reduction. They grind ores and other materials to a typical product size of 35 mesh or finer.

These are just a few examples of the types of industrial crushers used in various industries.

The choice of crusher depends on factors such as the type of material, required product size, capacity, and desired application.

Applications of Crushing Operation in Industries

Here are some typical applications of industrial crushers in chemical manufacturing:

Raw Material Preparation: Industrial crushers are used to prepare raw materials for chemical manufacturing processes. They can reduce the size of bulk materials such as minerals, ores, and chemicals, making them suitable for further processing. Crushers like jaw crushers or gyratory crushers are commonly used in this stage to crush large-sized materials into smaller particles.
Mixing and Blending: Crushers can be employed to facilitate the mixing and blending of chemicals. By reducing the size of solid materials, crushers help achieve better homogeneity and facilitate the combination of different components. This is particularly important in producing chemical compounds, where precise mixing is necessary to ensure consistent quality and desired properties.
Reaction Enhancements: Industrial crushers can be used to enhance chemical reactions by increasing the surface area of solid reactants. By reducing the particle size, crushers expose a larger surface area, leading to more efficient and faster reactions. This is crucial in processes like grinding and pulverizing, where crushers like hammer mills or impact crushers are commonly utilized.
Catalyst Preparation: Chemical reactions often require catalysts to enhance reaction rates or enable specific transformations. Crushers are used in the preparation of catalysts by reducing the size of precursor materials. This enables better mixing, surface area exposure, and uniform distribution of the catalyst, leading to improved catalytic activity.
Product Formulation: Industrial crushers are involved in the formulation of chemical products, such as powders, granules, or pellets. By reducing the size of raw materials, crushers help achieve the desired particle size distribution and physical characteristics of the final product. This is particularly important in applications like fertilizer manufacturing, where crushers are used to create uniform-sized granules.
Waste Management: Crushers are utilized in the chemical industry for waste management purposes. They can help reduce the volume of waste materials, making them easier to handle, transport, or dispose of. Crushers like shredders are commonly used to process chemical waste, including plastic waste, hazardous materials, or expired products.

Here are a few examples of various industrial applications of crushing equipment:

Mining Industry: In the mining industry, companies utilize industrial crushers to extract valuable minerals and ores from the earth. For instance, large jaw crushers or gyratory crushers are commonly used to break down ore into smaller pieces before further processing. Cone crushers and impact crushers may also be employed for the secondary or tertiary crushing of minerals.
Chemical Manufacturing: Chemical manufacturing companies often rely on industrial crushers to process raw materials and facilitate production. For example, crushers are used to crush and grind solid chemicals, such as salts or powders, for further formulation or to achieve a specific particle size distribution. Hammer mills, roll crushers, or impact crushers can be used in this context.
Construction and Demolition: In the construction industry, crushers are employed to process construction and demolition waste. Companies use crushers to reduce the size of concrete, asphalt, bricks, and other construction materials, turning them into reusable aggregates. Crushers such as impact or jaw crushers are commonly used for this purpose.
Recycling Industry: Recycling companies rely heavily on industrial crushers to process various recycling materials. For instance, crushers are used to crush and shred materials like plastic, glass, metal, and paper, facilitating recycling processes and reducing waste volumes. Shredders, hammer mills, or granulators are commonly utilized in recycling operations.
Food Processing: In the food processing industry, crushers are used to break down and process various food ingredients. For example, industrial crushers can be used to crush fruits, vegetables, or grains to extract juice or oils. They can also be employed to grind spices, herbs, or coffee beans. Specialized crushers designed for food processing ensure hygiene and maintain product quality.
Pharmaceutical Industry: Pharmaceutical companies may use industrial crushers during the manufacturing of medications. Crushers can be used to crush and grind active pharmaceutical ingredients (APIs) or other solid materials to achieve the desired particle size or formulation. They are often employed in tablet manufacturing or powder processing operations.

Conclusion

In conclusion, crushing equipment is vital in various industries, ranging from mining and construction to chemical manufacturing and recycling. The primary purpose of crushing equipment is to reduce the size of materials, making them more manageable for further processing or disposal.

We explored the definition of crushing equipment, which involves the application of mechanical force to break down materials. The working principle of crushing equipment varies depending on the type of crusher used, such as compression, impact, shear, or attrition. Each mechanism is designed to achieve specific particle size reduction and material processing goals.

Furthermore, we examined different types of crushing equipment commonly used in industrial settings, including jaw crushers, impact crushers, cone crushers, gyratory crushers, roll crushers, hammer mills, and shredders. Each type of crusher has unique features and advantages suitable for specific applications and material characteristics.

Finally, we discussed the wide range of applications for crushing equipment. In the mining industry, crushers are used to extract valuable minerals from ores. In chemical manufacturing, crushers assist in raw material preparation, catalyst formulation, and waste management. Construction and demolition companies utilize crushers for processing construction materials while recycling companies rely on them for recycling processes. Additionally, crushing equipment finds applications in food processing and pharmaceutical industries for ingredient extraction and formulation.

Industrial Crushers : Working, Types and Applications Explained - Core Chemical