The impact crusher for example has a higher co efficient of reduction produces crushed material with an optimal cubic shape for asphalts and concretes allows faster and simpler maintenance has a lower acquisition cost gives continuous production curves with no irregularities or breaks between sizes see Figure 1 permits bigger feed sizes and delivers higher production of small sizes The cone crusher on the other hand has the advantage of fewer wear parts.
The vast majority of impact crushers have been conceived and designed to process relatively soft stone Accordingly their construction materials and components are strong enough to cope with this kind of material but are generally insufficiently robust to crush harder more abrasive materials such as granite flint basalt and iron ore.
However what would happen if impact crushers could match cone crushers in terms of performance and wear costs In emerging markets such as Russia Africa east Asia and South America among others cone crushers are increasingly being replaced by impact crushers in granite and basalt quarries providing an improvement in the quality of crushed material and a reduction in the cost per tonne thereby increasing the competitiveness of some companies against their local rivals.
But how have impact crushers reached the wear parameters of cone crushers In the past the use of impact crushing for hard and abrasive stone was mostly limited to very small niche markets especially in countries such as Spain and Germany It was in markets such as these that the impact crusher evolved and matured for 50 years to become the trusted product it is today.
Based on innovation and experience and an awareness of the advantages and disadvantages of impact crushers compared with cone crushers and the opportunities that this implies in overcoming the problem of wear a few manufacturers have worked on two key areas improving impact crusher efficiency and wear parts management and developing the technology of the materials from which the parts are made.
Image3 ar w620The development of ceramic chrome alloys to increase the durability and abrasion resistance of wear parts together with evolution in the management of these parts during use has resulted in a significant reduction in the cost per tonne of material produced.
The smaller the output size the more competitive impact crushers become because their percentage of finished product in the first pass is considerably higher than cone crushers Combined with an upgrade to wear parts materials this can allow impact crushers to reach a lower wear cost ratio per tonne than cone crushers see Table 1.
While it cannot be denied that the useful hours of impact crusher wear parts have not yet reached the useful hours of cone crusher wear parts in tertiary stage works they have been upgraded enough to be a better option than cone crushers in some situations allowing them to reach figures such as those shown in Table 1.
For secondary stage works impact crushers have equalled cone crushers overcoming all their disadvantages and matching their main advantage the wear cost ratio.
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