Ambo University

Department of Mechanical
engineering

Heavy duty and Construction

Equipment
MEng5383

Chapter-six

Crushers

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 Introduction
 Crushers are used mainly to reduce the size of large
stone or rock to smaller uniform sized aggregates
required for concrete mix.
 There are four basic ways to reduce size of a
material:
 Impact
 compression,
 Shear
 attrition.
 Most crushers employ a combination of all these
crushing methods.
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Impact
Impact refers to the sharp,
instantaneous collision of one
moving object against another.

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 compression
Crushing by compression is done
between two surfaces, with the
work being done by one or both
surfaces.

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 Attrition
Attritionis the reduction of materials
by scrubbing it between two hard
surfaces. However, attrition
consumes more power and exacts
heavier wear.

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 Shear
Shear consists of a trimming or cleaving
action.
Shear is usually combined with other
methods. For example, a single-roll
crusher, employ shear together with
impact and compression.

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 TYPES OF CRUSHERS
• Crushers are classified according to the stage
of crushing which
they accomplish, such as:
 Primary
 Secondary
 Tertiary
 A primary crusher receives the stone directly
from a quarry after blasting, and produces the
first reduction in size.
 The output of the primary crusher is fed to a
secondary and tertiary crusher, which further
reduces the stone size.
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TYPES OF CRUSHERS
Crushers are also classified by
their method of mechanically
transmitted fracturing energy to
the rock.
i. Jaw crushers
ii. gyratory crushers
iii. Roll crushers
iv. Impact crushers

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Jaw crushers
It is one of the primary crushers.
 It operates by allowing stone to flow into
the space between two jaws, one of which
is stationary and other is movable, which
together constitute the crushing surfaces.

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 Working principle of jaw crusher
A jaw crusher uses compressive force
(mechanical pressure) for breaking of particles.
 Essentially a jaw crusher consists of two plates,
set at an acute angle to each other, with one
jaw pivoted (swing jaw), so that it swings
relative to the other (fixed jaw).
 The inertia required to crush the material is
provided by a weighted flywheel that moves
the eccentric shaft.
 The volume or cavity between the two jaws is
called the crushing chamber.

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 When the swing jaw moves forward, the
pressure required to crush the material is
generated because the crushing chamber
narrows and the material gets crushed.
 When the swing jaw moves back again, the
material crushed to the size of the pre-selected
jaw opening exits the crushing chamber at the
bottom due to gravity while new material flows
in from the top.

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Jaw crushers

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Types of Jaw Crushers
jaw crushers are generally
classified by the method of
pivoting the swing jaw
 Blake type jaw crusher, the swing
jaw is pivoted at the top (upper
position).
 dodge type jaw crusher, the
swing jaw is pivoted at the
bottom (lower position).
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Jaw Crusher Terms
 Feed Opening: It is the distance between the
jaws at the feed opening. Feed opening defines
the maximum feed size of the crusher.
 Open Side Setting (OSS): It is the maximum
discharge opening/gap.
 Throw/Stroke: It is the difference between OSS
and CSS

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 Jaw Crusher Terms
 Closed Side Setting (CSS): It is the minimum
discharge opening/gap. It is the most important
crusher parameter since it defines the
maximum product size.
 Nip Angle: The nip angle is the angle between
the fixed and movable jaw plates.

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Capacity of jaw crusher
Lewiston developed the following formula
for the capacity determination of jaw
crushers.

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Example 1:
Calculate the capacity of a jaw crusher; the available data
are: rpm of the main drive shaft is 170, width of swing jaw is
1.2 meter; amplitude of swing jaw is 45 mm. Mean size of
the crushed material is 0.17 meter; spec. gravity of crusher
feed is 2.7 tons/cu.meter.
Given
rpm of drive shaft is (n) =170
width of swing jaw (b) = 1.2 m
amplitude of swing jaw (s) =45 mm = 0.045 m
Mean size of the crushed material (d)= 0.17 m
spec. gravity of crusher feed (r) = 2.7 tons/cu.meter

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Drive power
According to Lewenson
‘formulate the drive power of jaw
crushers is calculated as follows:

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Example
Calculate the motor size of a jaw crusher; if
the Width of crusher jaw 1.2 meter, revolutions
of the main shaft are 170 rpm. Dimensions of
crusher feed 0.50 m; dimensions of crushed
material 0.17 m.

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 Gyratory crusher
 Gyratory crusher is generally used as a primary crusher.
 This type of crusher comprises a hardened steel head has a
long conical shape, with a trough shaft suspended in a
bearing at the top, and an eccentric base connection
connected to gears.
 The rock is feed into the chamber at the top and as it moves
downward, crushing is done and finally emerges through the
bottom gap.

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Working principle of Gyratory crusher
A gyratory crusher uses a mantle that gyrates
(rotates) within a cone shaped inner surface
lined with wear resisting plates often called
concaves.
 As the mantle gyrates within the rushing
chamber, progressively approaching, and
receding from, each element of the cone shaped
inner surface, it creates compressive force,
which fractures the material.
 The feed material that is fed into the crushing
chamber from above is progressively crushed
between the crushing elements (mantle and
concaves), finally exiting the crushing chamber
at the bottom under the influence of gravity.

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 Cone crusher

 Cone crusher are used as a secondary or

tertiary crusher.
 These crusher are capable of producing large
quantities of uniformly fine crushed stone.
 It has a shorter cone with smaller inlet and
outlet openings as compared to the gyratory
crusher.

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Capacity of cone crusher

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Capacity of cone crusher
Example
The diameter of base of crushing cone
is1.65m, mean size of the crushed
material is 15 mm, stroke number is
240 rpm and the specific gravity of
crusher feed is 2.6 tons per cubic meter.
calculating the capacity of a cone
crusher?

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 Roll crusher
 Roll crushers are used for primary as well as
secondary and tertiary stages.
 This crusher consists of a heavy cast iron frame
equipped with one or two rotating rollers
mounted on a separate horizontal shaft.
 The crushed rock from the primary crusher is
feed through the gap between the two rollers for
crushing further.

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Types of Roll crushers
Roll crushers are of two types:
 single roll crusher
 double roll crusher.
Single roll crushers are typically
used as primary crushers.
Double roll crusher are typically
used in situations in which fines are
to be minimized.

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Single Roll Crushers
A single roll crusher consists of a roll assembly
and a breaker plate. In these crushers,
reduction occur due to impact, shear and
compression.
 sometimes, comb teeth-like projections are
provided at bottom of the breaker plate, which
are duly hard-faced by special electrodes of
wear-resistant quality.

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Working Principle of Single Roll
Crushers
 As material enters the crusher through the feeder hopper,
it is struck by the teeth of the revolving roll and initial
breakage occurs from the impact.
 The rotation of the roll then guides the material further
into the crushing chamber, the space between the
breaker plate and the roll itself.
 The roll then pinches the material against the stationary
breaker plate(impact), and simultaneously, the material is
crushed by the shearing action of the roll teeth and by
compression, providing final sizing.
 The crushed material exits through the bottom discharge
portion of the crusher.

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 Double Roll Crushers
 Double roll crusher consists of two parallel
rotating rolls turning together (in opposite
directions and turning in the direction of the
downward material flow through the center),
with feed being directed through the moving gap
between them.
 The rolls are individually powered or coupled by
gears.

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Working Principle of Double Roller Crusher
 The crushing material is fed into the crusher
such that it is spread over the whole width of
the rollers.
 As the two rolls rotate toward each other, the
material is pulled down into the crushing zone
where it is grabbed and compressed by the
rolls; and crushing is primarily accomplished by
compression.

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Impact Crushers
 Impact crushers consist of a high speed
rotating impeller or hammer, which accelerates
the incoming new feed to high speed, to
impact against a wear liner to cause rock
breakage.
 The products of these crushers are generally
quite fine due to the large amount of power
exerted on each particle as it passes through,
causing shatter type fracturing.

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Types of impact crushers
The two general types of impact
crushers are:
 Horizontal Shaft Impactors
 Vertical Shaft Impactors

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Horizontal Shaft Impactors
The horizontal shaft impactor (HSI) has a
shaft that runs horizontally through the
crushing chamber with a rotor that turns
hammers or blow bars.
It uses the high speed impacting force of
the turning blow bars projections to break
the material.
Horizontal shaft impactors are suitable for
crushing hard rocks such as limestone,
dolomite, granite and other similar
materials under toughest operating
conditions.
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 Construction and Working of Horizontal
Shaft Impactor
 The figure below shows construction of a typical
horizontal shaft impactor. The rotor has wedge
shape grooves extending parallel to the shaft for
holding blow bars.
 The rotor is equipped with two, four or six blow bars.
The blow bars extend over the full width of the
rotor. The bars are so designed that they can be
used by turning them after one face wears out.
 Two or three aprons (breaker plates) are positioned
to form an arc of the circle centered to the point of

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 Working of Horizontal Shaft Impactor
 After entering the crushing radius of the rotor, the
feeding material is broken by primary impact of
the blow bars and the material propels towards
the first apron (liners) where it is broken by
secondary impact.
 The material is then shot back from the apron to
the blow bars. The material is also broken in the
crushing chamber by material hitting material.
 The process repeats until the material is crushed
to the required size and discharged through the
discharge opening at the bottom of the machine.

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