VSI for Sand Production Facilities

VSI for Sand Production Facilities

What is a Vertical Shaft Impact Crusher (VSI)?

Vertical Shaft Impact (VSI) crushers are a type of impact crushers that are used primarily for the last crushing stage before grinding, offering a crushing mechanism that yields products with a more cubical shape. The mechanism involved is quite simple yet effective: stones are thrown against a high-speed rotor with open table configurations and thrown back from the anvils or stone shelves at high speeds. This action breaks the material by impacting it against a fast spinning rotor, anvils, and the shatter boxes. VSI crushers are particularly successful in producing road-base, top dressing chip, concrete and asphalt aggregates, and manufactured sand.

The unique feature of VSI crushers is the process used for breaking the stones. Unlike other types of impact crushers that use strike bars to shatter the material, VSI crushers utilize the feed material itself for breaking under high-speed rotor action. This material is accelerated by centrifugal forces toward the periphery of the rotor, where the high-speed rotor impacts and fractures the material along its natural fault lines. This results in a more consistent, cubical shape which is preferred for modern concrete and asphalt applications, where particle shape and size are important for strength and durability.

In which areas is the Vertical Shaft Impact Crusher (VSI) used?

Production of Manufactured Sand

Vertical Shaft Impact (VSI) crushers are extensively used in the production of manufactured sand, which is used for various construction applications. This type of crusher excels at producing fine particles of sand that meet the size and shape specifications for construction projects. VSI crushers use a high-speed rotor and anvils for impact crushing rather than compression force for the production of materials with precise shapes and sizes. The result is high-quality sand that can be used as a substitute for natural sand, which is becoming increasingly scarce due to over-extraction.

Manufactured sand from VSI crushers is ideal for concrete and plastering uses due to its consistent grain size and low presence of deleterious materials. Using VSI technology, businesses can process fine aggregates that adhere strictly to global standards and regulations, thus fulfilling the rising demands of the construction industry. This contributes significantly to environmental sustainability by reducing the dependency on river sand.

Production of Cubical Aggregates

Another essential application of VSI crushers is in the production of cubical aggregates. These aggregates are highly sought after in the construction of roads and other infrastructure due to their superior mechanical properties. The cubical shape enhances the aggregate interlock and load-bearing capacity, which is crucial for the foundation layers of roads. VSI crushers achieve this desired cubical shape by striking material at high speed against hard surfaces, thereby fracturing along its weakest planes.

Cubical aggregates produced by VSI crushers are also preferred for their aesthetic appearance and are commonly used in visible parts of construction sites, such as landscaping, pathways, and driveways. Besides enhancing structural integrity, these aggregates lend a neat and organized look to construction projects, adding to their commercial value.

Recycling Applications

VSI crushers play a pivotal role in recycling applications where they are used to process materials like glass, concrete, and asphalt debris into reusable aggregates. The high-speed impact actions of the VSI crushers efficiently reduce these materials into smaller particles, making them easier to repurpose. This capability not only helps in reducing the waste going to landfills but also promotes sustainable construction practices by providing an eco-friendly alternative to disposing of construction waste.

By converting old and discarded materials into high-quality, reusable aggregates, VSI crushers aid in environmental conservation and provide economic benefits through cost savings in waste management and new material production. Recycled aggregates are used in various applications, including base material for roads, driveways, and as aggregate in new concrete, demonstrating the versatility and utility of VSI technology in recycling operations.

What are the advantages of Vertical Shaft Impact Crushers (VSI)?

Vertical Shaft Impact (VSI) crushers offer several distinct advantages over other types of crushers, particularly when it comes to creating precise, cubical aggregates and manufactured sands. One of the primary benefits is their ability to produce a high percentage of product in the desired cubic shape. This cubical configuration is crucial for the production of high-quality concrete and asphalt aggregates, ensuring that the materials have improved durability and structural integrity. Additionally, the fine crushing capability of VSI crushers allows for the production of high-quality manufactured sand, which is becoming increasingly important as natural sand reserves deplete worldwide.

Another significant advantage of VSI crushers is their efficiency. These crushers utilize high-speed rotors and wear-resistant tips that reduce the material by impact and attrition processes, which can be much more energy-efficient compared to other crushing methods. The design of VSI crushers also allows for minimal downtime and lower maintenance costs because they have few moving parts and use rock-on-rock crushing to wear parts evenly. Furthermore, VSI crushers are adjustable, meaning that they can be tuned to produce different sizes and shapes of output material as required, adding to their flexibility in various industrial applications.

How do Vertical Shaft Impact Crushers (VSI) work?

Vertical Shaft Impact (VSI) crushers operate by propelling rocks against a high-speed rotor at high velocity. The material is fed into the center of the rotor, where it is accelerated to speeds of up to 80 m/s (262 ft/s) by the centrifugal force created by the rotating rotor. As the rocks come into contact with the rotor, they are crushed into smaller pieces upon impact. Subsequently, the fractured particles are flung outward against the anvils or rock shelves that line the crushing chamber. This high-velocity impact not only reduces the size of the input material but also shapes it into fine, cubical particles that are desirable for various industrial applications such as concrete production, road construction, and manufactured sand.

The unique crushing mechanism of VSI crushers distinguishes them from traditional cone or jaw crushers. Instead of utilizing compression force to break the material, VSI crushers rely on the rapid acceleration of rocks within the crushing chamber to achieve the desired particle size reduction. The open design of the rotor and the anvils allows for the material to be subjected to multiple impacts, ensuring efficient crushing and shaping of the input material. This process of impact and attrition not only helps in producing uniform and cubical-shaped aggregates but also minimizes internal stress within the material, resulting in high-quality end products preferred in construction and manufacturing industries.

Pioneer in Innovative Technology: Polygonmach

POLYGONMACH is a leading global manufacturer of concrete batchingplants, crushing screening plants, and asphalt plants. With TSE and ISO 9001 quality assurance certifications ans a commitment to innovation, quality, and customer
satisfaction, we have established ourselves as a trusted name in the construction industry. Our extensive range of high-performance plants caters to the diverse needs of construction projects, ensuring efficiency, reliability, and durability.

 

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