Crushing with Impact
Crushers are a vital part of any operation so choosing the right one is critical. Here’s a guide to the impact crushers on the market today to help guide your decision.
by Therese Dunphy, Editor-in-Chief
Sculptured rotor with high inertia
Telsmith Inc.’s new PA6060 Primary Impact Crusher, which will be on display at next month’s ConExpo-Con/Agg trade show in Las Vegas, is designed as a primary crusher for either quarried stone or recycling concrete. The Andreas-style impact crusher has a 59-inch, solid-type sculptured rotor that combines high inertia with the ability to handle up to a 40-inch feed. The oversized 220-millimeter-wide series roller bearings are larger than industry standards, which assists in extending service life beyond the typical timeframe. Adjusting the crusher’s apron setting can be easily done with handheld controls, and an automated apron reset feature simplifies crusher operation. Hydraulic controls on the crushers are equipped with position sensors to provide “dependable relief” when encountering tramp metal, according to the company. A hydraulic tilting plate on the impactor provides operators with an easy way to clear amp-ups and bridging — and handheld controls tilt the plate for quick and safe clearing. Additionally, heavy-duty, mono-block aprons provide long life and are interchangeable throughout the crusher. The impactor can be mounted on portable plants or into fixed locations with truck-dump feed arrangements.
Lowest cost-per-ton for tough applications
The Eagle Crusher 1600-69, which is part of the company’s UltraMax Series, is said to be highly versatile and self-contained and to produce cubical product at a lower cost-per-ton in tough aggregate and recycling applications. The crusher features a 13-ton sculptured, three-bar rotor made of solid steel and has a fully lined hopper and 68-inch by 20-foot feeder. The impactor weighs 61,000 pounds and has a plant weight of 77,800 pounds in transport mode, 170,000 pounds complete. The travel width is 11-feet, 11 inches and travel height is 13 feet, 5 inches. Rotor diameter and width is 56 by 68 inches. The feed hopper capacity is 27 cubic yards.
Two machines in ones
Kleemann Inc. USA’s Mobirex MR 130 Z mobile impact crusher is a high-capacity machine that is two machines in one — a crusher and a screen box on one chassis. The high-capacity machine enables limestone, reinforcement demolition concrete, tiles and bricks, and reclaimed asphalt pavement (RAP) to all be processed by this hydraulically driven impact crusher to produce a high-quality, graded product. The crusher’s variable rotor speed and impact rocker adjustment ensure uniform and product quality when variable or non-homogenous feed material is used, according to the manufacturer. The feeder opening is 51 by 35 inches, and the crusher can accept material up to 43 by 2 inches in size. The maximum throughput is 440 tons per hour. The machine is closed circuit and has a fully independent pre-screen.
Large reduction ratio
The I-1312 impact crusher from Terex Finlay is a multiple-speed impact crusher designed for primary and secondary crushing of concrete/asphalt rubble and limestone. It features a high throughput and large reduction ratio as well as a rapid setup, according to the manufacturer. The I-1312 uses a high-performance Cedarapids 5048LP impact crusher with a large discharge opening and standard three-bar or four-bar configuration. Other standard features include a hydrostatic drive and advanced electronic control system, hydraulically assisted apron setting, grizzly feeder with integral pre-screen, selectable discharge to bypass or main conveyor, and dust suppression on the main conveyor.
The crusher’s hopper capacity is 11.7 cubic yards and has hydraulically folding sides, 5/8-inch hardox sidewalls, and tapered grizzly apertures. It also has an integral 5-foot by 4-foot screen, heavy-duty counter rotating shafts, oiled bearings, and an advanced CANBUS-compliant control system that has five operating modes — track, manual, automatic, configuration, and language — with a menu-driver user interface. A detachable, dog lead control for tracking or optional full-function radio remote also is available. Other options include a bypass conveyor, overband magnet, belt weigher, extra dust cover for discharge conveyor, hydraulic water pump, recirculation conveyor, tracked or wheeled undercarriage, and a CAT C13 (Tier 3) engine.
Produces multiple material sizes
The Andreas Series horizontal impact (HSI) crusher from KPI-JCI can accommodate two-, three-, or four-blow bar configurations. They are equipped with the company’s maximum performance rotor, providing operators with the flexibility of an open configuration. An easily adjustable apron provides quick setting changes, and the replaceable liners protect the crushing chambers. This series has production capacities up to 450 tons per hour.
The company’s New Holland Series HSI crushers feature models with feed openings that range from 38 to 50 inches to 60 to 64 inches. The rotor has easily adjustable impact bars that provide quick-setting changes appropriate in multiple aggregate and recycling applications. The New Holland Series has production capacities up to 1,019 tons per hour and is available in stationary and portable configurations. Wear-resistant manganese sleeves help to protect against abrasive wear, and an adjustable impact bar provides the flexibility to produce multiple material sizes.
Automatic, hydraulic cylinder
Grasan’s largest pit- or road-portable primary impact crushing plant, the KRH1515, can be configured for concrete/asphalt recycling (side discharge) or crushing limestone (end discharge), providing reduction ratios as great as 30 to 1 in a closed circuit. The plant features the Hazemag APPH impact crusher with a fully automatic, hydraulic cylinder system that provides increased crusher capacity up to 600 tons per hour, smoother operation, and more uniform products. Crusher adjustments also have been simplified so no tools are needed. The crusher inlet is 45 inches high ⎯ 10 inches greater than previous models ⎯ to handle larger sizes of incoming material, and a hydraulic moveable inlet base helps clear jamming and bridging. The hydraulic inlet hood is secured with wedge pins for easy opening and closing. To reduce users’ spare parts inventories, side liners in the crusher have been reduced from seven to three standardized shapes and all multi-blocks have been made interchangeable. The crusher’s grizzly bypass chute makes it easy to keep or reject undersize material, according to the company. It is available with diesel or electric power, and the road-portable model includes a skid-on, skid-off hopper and six independent hydraulic support legs for easy set-up and teardown without a crane.
Continuous flow design
The 6500LP Crushing Plant from Lippmann features a flow design that doubles production when compared to competitive plants with the combination of a larger feeder, impact crusher, and screen deck, according to the manufacturer. The plant’s typical product flow has been re-engineered into a continuous flow design that allows rebar to bend and material to discharge smoothly with the rotation of the rotor for uninterrupted production. This flow design is able to handle rebar as long as 10 feet. A heavy-duty pan feeder under the crusher prevents conveyor belt damage. The plant’s on-board conveyors mean that only two pieces of equipment — instead of four — need to be moved to a job site, and its relatively small footprint provides flexibility to confirm to site constraints.
Maximizes one-pass product yield
The Mega Slam Primary & Grand Slam Secondary Horizontal Impact Crusher from Stedman features two new product developments — the Crush Plus Grinding Path System and the Max-Yield Automated Apron Adjustment System. The Crush Plus system creates a third crushing chamber to maximize one-pass product yield, minimize oversize material, improve material soundness, and produce a highly cubical product. The Max-Yield maintains gap-setting adjustment for aprons and the grinding path and is controlled by a Programmable Logic Controller (PLC) that is said to improve one-pass product yield and reduce product changeover downtime.
Patented ‘center-pull’ wedge system
The 1300 Series Horizontal Primary Impact Crushers from Terex Cedarapids — IP1313 and IP1316 — feature an enlarged feed opening (43-1/4 by 64-3/4 inches for the IP1316) capable of handling large, irregular-shaped feed materials. Both crushers in the series have heavy “monoblock” primary plates, reinforced secondary breaker plates, hydraulic-assist adjustment systems, and high-inertia rotors with a patented “center-pull” wedge system — all of which have been designed for high capacity and large-feed size. The low-profile design allows for crusher installation as well as both wheeled and tracked machines. Within the series itself, the IP1313 and the IP1316 process a high-tonnage of material, provide “excellent” control over particle shape and size, and process myriad types of materials, including those for recycling applications, according to the company. The series is available in two sizes and with two crushing chamber configurations and with two- or three-bar rotors that come in 5-inch, one-piece cast impeller bars made from either manganese steel or tool steel. Other standard features include replaceable feed plate liners; a left-hand drive; spring-loaded secondary apron; replaceable 3-inch thick high-chrome secondary apron lines; a 5 horsepower electric/hydraulic power unit; and a flanged feed opening that accepts feed adapters. Optional equipment includes a V-belt drive; a right-hand drive; two-bar impeller rotor; tool steel secondary apron liners; bolt-on feed adapter with chain/rubber curtain; a 53-inch high-inertia sheave; and several drive-sheave options.
Screen Machine Industries
Fully remote-controlled operation
Screen Machine Industries, Inc. has added the 5256T tracked, portable impact crusher to its product line. It is a fully remote-controlled operation featuring standard Caterpillar tracks and its C-15 ACERT Tier 3 479 horsepower diesel engine as well as a 52- by 56-inch horizontal impact crusher with a 56- by 38-inch feed inlet opening. The crusher also featured a patented split-housing design that allows for blockage clearance during operation as well as making maintenance easier. A wireless remote control triggers the lifting lid, which allows oversized material to pass through the crusher without stopping.
Construction Equipment Co.
Hydraulic self-adjusting clutch
The 102×115 (40 by 45 inches) Track Mobile Impactor from Construction Equipment Co. (CEC) has a hydraulic self-adjusting clutch with push-button startup. The crusher weighs 68,000 pounds, and a magnet adds 3,100 pounds to the weight. The 40-inch by-12-foot feeder features 60-inch long grizzly bars, bolt-in wear liners, bolt-in adjustable bars in 1-1/2 to 3-3/4 inches, an enclosed dual-shaft eccentric, drive mounts on the eccentric housing, an under grizzly reject chute, and a grizzly side reject chute. The system has dual-adjustable curtains, replaceable chute liners, and a balanced rotor. There are three rows of blow bars, with 830 pounds of blow bars per row, as well as top-loading blow bars. Other features include a hydraulic debridger, a 4- by 8-inch backing bar with replaceable seats, a hydraulic hood opening, fixed exit curtains, and wind stripper bars.
Single-wedge hammer locking system
The Sandvik Impactmaster P&S Series from Sandvik Mining & Construction has a hammer locking system that is composed of a single wedge, bolt, and spring washers at each locking point, which firmly secures the hammers both vertically and horizontally. The crusher also features a self-sharpening leading edge, a rotor design that delivers high inertia, and an optimized modular concept for compatibility with all of the company’s 16 primary and secondary crusher models. Several options are available for the crusher, including a motor-driven hydraulic power pack for curtain-setting assistance and crusher topshell opening; manganese, chrome steel, and/or chrome iron for hammers and liners (depending on the application); a jib crane for removing and replacing hammers; and a re-circulating chute, which enables a P series crusher to operate in a closed circuit. According to the manufacturer, this crusher series is the most advanced line of impact crushers available and have a high-reduction ratio and a high-quality cubical product.
Hydraulic apron-locking mechanism
The Terex Pegson 1412 Trakpactor plant features a horizontal impact crusher with hydraulic controls, which the company says makes more uniform products, and the latest programmable logic controller (PLC) CAN BUS control system to automatically regulate the feed to the crusher, based on the engine load. The plant is suitable for crushing concrete and asphalt rubble, brick, and medium to hard limestone. The impactor uses a hydraulic apron-locking mechanism with overload protection and automatic reset, providing consistent product size and added protection against tramp metal. The crusher also opens and adjusts hydraulically, and it is fitted with a hydraulic tilting feed plate to improve blockage clearance. The feed opening is 32 by 54 inches, and the rotor size is 48 by 53 inches with reversible steel blow bars that are held together with a simple clamping system. Ceramic blow bars are optional. Maximum feed size is 24 by 20 by 20 inches cube or 48 by 40 by 20 inches slab. The standard hydraulic folding feed hopper has over-center struts and a wedgelok system and is a grizzly feeder with a 54-inch by 14-foot underscreen.
Hydraulically adjustable feed plate
Universal Engineering’s MaxCap Primary Impact Crusher can crush up to 1,400 short tons per hour and boasts a hydraulically adjustable feed plate; interchangeable back and top wall castings; a hydraulically adjustable breaker plate that automatically maintains its position; and a heavy-duty disc style rotor with quick-change hammers. The crusher offers the capacity of a New Holland style crusher with the ease of operation and maintenance of an Andreas style machine, according to the company. The standard design of the MaxCap features the following: heavy-duty fabricated steel construction; an upper section of the housing that retracts hydraulically for easy access to the interior of the impactor; hydraulically adjustable feed plate and breaker plate with automatic positioning; a fabricated disc-rotor assembly with quick-release hammer locks, and a rotor lock pinned from the crusher housing into the rotor body. The crusher also has top-loading, reversible hammers with protruding leading edges, interchangeable abrasion-resistant alloy steel liners to protect the interior walls of the crushing chamber, and large access doors on the side and back of the crusher. Optional equipment includes an electric motor, jib crane, crusher sheave, drive guard, motor sheave, V-belts, and feed chutes designed for specific applications.
Re-circulation system produces maximum throughput
Extec Screens & Crushers’ I-C13 impact crusher features a re-circulation system that is able to produce maximum throughput when creating a highly useable product, in a single pass. The crusher can work through the high temperatures and masses of dust and dirt, without being prone to failure, according to the company. The system’s optional re-circulation system ensures that a consistently high-quality product is produced, reducing the need for further processing steps. It also has the option of a bogie transport system that enables simple movement over any distance, without the need for a low loader. A compact, heavy steel web and flange construction allows for improved strength and reliability, and a Caterpillar C-13 industrial engine ensures maximum power, even in the harshest conditions. Key design features of the chassis, such as the wide-discharge point between the crusher and main conveyor, allow for reductions in any blockages while facilitating machine maintenance and cleaning. The use of hydraulic lifting legs allow for simple track and underside maintenance.
Engineered for mobile applications
Metso Minerals has developed new Nordberg (NP) Series impact crushers — the NP1110M for the LT1110(S) and NP1213M for the LT1213(S) crushing plants — and have been engineered specifically for mobile applications. The crushing capacity for the 1110M and NP1213M is 260 tons per hour and 350 tons per hour, respectively. Both impact crushers feature a unique combination of heavy rotor design, wear material, and crushing chamber design that result in improved capacity, product quality, and a reduction in operation and wear costs, according to Metso. The NP1110M features a 41- by 31-inch crushed-feed opening, a maximum feed size of 23.6 inches, and it weighs 20,240 pounds. Its recommended speeds of operation range from 450 to 600 rpm.
The NP1213M features a 52- by 33.2-inch crusher feed opening, a maximum feed size of 25.6 inches, and a weight 27,000 pounds. Its recommended operational speed is 450 to 600 rpm. Both models feature a heavy monobloc breaker plate that has the same geometry as a two-breaker plate machine and a retractable lifting beam with manual hoist.
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