What are the advantages and usage areas of Tertiary Impact Crusher?

What is a Tertiary Impact Crusher, and what is a Horizontal Shaft Crusher?

A tertiary impact crusher is a tool used in the final cycle of crushing, which aims to bring out the desired particle size of the material. It is designed for fine materials and most of the time gives a high-quality, uniform product. This kind of crusher is truly useful in areas where precision is key, such as in sand or fine aggregate production. Tertiary impact crushers are third-generation impactors whereby material is reduced through high-speed rotor movement and impact plates to fracture materials to desired specifications. In such mills, materials like limestone, asphalt, and concrete are usually processed.

A horizontal shaft crusher is one of the varieties of impact crushers. The rotor revolves horizontally between the cranking shaft in executing crushing. This crusher incorporates a high-speed rotating shaft carrying hammers or blow bars that are generally wear-resistant. This design is particularly effective in crushing soft to medium-hard materials, such as limestone and gypsum, found in aggregate production, recycling, and mining. The horizontal arrangement assures correct reduction of large-sized products while offering flexibility to achieve various crushing ratios and product sizes by adjusting rotor speed and crusher settings.

What is the difference between a Vertical and Horizontal shaft?

  1. Vertical Shaft Impact Crushers (VSI)

a. Design and Operation

VSI crushers have a rotor configuration in a vertical axis. Material to be crushed is fed into the central chamber and is thrown against the walls of the chamber or a series of anvils by high-speed rotators. Vertical orientation lets it use a unique method of crushing through the action of high-speed impact that mostly results in fine and well-shaped products.

b.Applications

VSIs are applied in producing high-quality, well-shaped aggregates and sand. They find applications for concrete and asphalt industries where the shape and size of the aggregate particles are of prime importance. In the recycling industry, VSIs are also widely used for breaking recyclables, for instance, glass, slag, and industrial minerals.

c. Advantages

- Excellence in producing cubical and well-graded particles.
- Ideal for fine crushing and shaping applications.
Therein lies the versatility in the processing of a wide range of materials.

2. Horizontal Shaft Impact Crushers (HSI)

a. Design and Operation

HSIs take the form of a horizontal rotor configuration. Material enters a crushing chamber, where it comes into contact with fast-rotating hammers or blow bars fixed to the rotor. These hammers strike and break the material against impact plates or curtains placed around the rotor. The horizontal arrangement makes material breakdown possible as a result of a combination of impact force and shear.

b. Applications

HSIs find their application in primary, secondary, and tertiary crushing of hard rocks and minerals. They are particularly very effective for the processing of softer to medium-hard materials such as limestone, coal, gypsum, and other natural stones. HSIs are also normally used in recycling operations to process materials such as concrete and asphalt so that construction and demolition debris can be recovered and reused. Therefore, the elements of a HSI include the following: c. Advantages

- Prevalent in handling larger, coarse materials and primary stages of crushing.
- Versatile application from primary to tertiary crushing.
- Effluent for producing high reduction ratios and processing high-capacity throughput.

3. Key Differences:

a. Rotor Orientation

VS: Vertical rotor.
HS: Horizontal rotor.

b. Crushing Mechanism

VS: Employs high-speed impacts in a vertical chamber on the production of fine and cubic particles.
HS: Force of impact, shear caused by blow bars positioned horizontally will be the essence of breaking and reduction in the material size.

c. Applications

VSI: Fine, well-shaped aggregates and sand are appropriate for industries that make concrete and asphalt.
HSI: More extensive applications in terms of a range of materials to be crushed and the stage of crushing, including primary and recycling.

d. Product Output Characteristics

VSI: Produces a high-quality uniformity and cubical particle output, mostly utilized for specific shaping tasks.
HSI: Can accept more feed size and a larger quantity of size range for various crushing stages.

Both types do have their positive uniqueness and selection depends on the application needs, nature of material to be crushed, and product characteristics.

Which one is the best crusher?

Advantages of Tertiary Impact Crushers Over Primary and Secondary Crushers

1. Finer Crushing Capabilities

Tertiary impact crushers are intentionally designed for material reduction to finer particle sizes. Keeping in mind that primary crushers do their work of reducing big, raw materials and secondary ones provide medium-range crushing, tertiary ones excel in the output of more finely crushed materials, meeting certain size and shape requirements. This is the reason it is appropriate for fine aggregate and sand production needed to make good construction material.

2. Better Quality Output

The design and operation of tertiary impact crushers allow better control of the size and shape of the end-product. This brings in higher quality, consistent output with well-graded and uniform particles. More importantly, the quality of aggregate materials directly influences the durability and strength of the final product, particularly in industries involving the manufacture of concrete or asphalt.

3. Improved Efficiency

Advanced design features and technologies are shared by many tertiary crushers to make them more efficient and effective. These include adjustable settings that would allow operators to tune the crusher to specifications of materials required. This is due to the ability to produce effectively and economically finely crushed materials with reduced energy consumption and lower operating cost when compared to primary and secondary crushers, which are best suited for rough and bulk reduction.
4. Versatility and Flexibility

Applications of Tertiary Impact Crushers: These versatile machines are capable of handling from soft to medium-hard stones and minerals. They can be designed for various product sizes and shapes by changing rotor speed, impact plates, and other settings. Due to this flexibility, they are theoretically adaptable to a wide variety of applications that go beyond the standard crushing tasks and into recycling operations and specialized mineral products.

Tertiary Impact Crushers-Preferred Applications

1. Construction Industry

Tertiary impact crushers find their high-end application in the construction industry for the production of fine aggregates and sand. Finely crushed materials are highly important in making quality concrete, asphalt, and other construction materials. Thus, this ability to produce uniform and precisely shaped particles means better performance and durability regarding construction structures such as roads, bridges, and buildings.

2. Recycling Industry

Tertiary impact crushers in recycling operations are quite efficient at treating demolition waste by-product, such as concrete, asphalt, and bricks. This adds to the economies of recovery by transforming the wastes into fine reusable aggregates, thus contributing towards sustainable construction through landfill waste reduction and conservation of natural resources.

3. Mining Industry

Similarly, the mining industries employ tertiary impact crushers, as they become essential in mineral processing stages. Processes like the manufacturing of finely crushed minerals such as limestone, gypsum, and other materials prepare these raw resources for further processing steps milling and beneficiation. Their competence in generating consistent, fine particles helps optimize the overall effectiveness of the mining operation.

4. Industrial Mineral Applications

The tertiary impact crushers are those that are applied in industrial mineral organization, where precision and fine particle sizes play a critical role. This includes the manufacture of products such as glass, ceramics, and some types of chemical compounds, where the uniformity and fine grading of the raw materials are important for the quality and performance of the final product.

In conclusion, tertiary impact crushers have some advantages that set them apart from primary and secondary crushers in application, where finer, high-quality output is desired. It becomes one of the versatile and efficient machines that can handle a variety of materials and preferred in industries when precision and product quality are of paramount importance.