Analysis of applicable scenarios for different ore types

1. Applications where a cone crusher is more suitable
Material Characteristics: When limestone has a high hardness (e.g., compressive strength > 200 MPa) or contains a high level of impurities, the wear-resistant components of a cone crusher (e.g., crushing wall and mortar wall) are more durable.
Production Requirements: a. Large-scale production lines require stable secondary or tertiary crushing, such as mining projects with annual output exceeding one million tons.
b. Applications where high particle size uniformity is required and excessive fines production is undesirable (e.g., for roadbed stone).
Environmental Requirements: Low operating noise, suitable for areas with strict environmental requirements.
2. Applications where an impact crusher is more suitable
Material Characteristics: Limestone has a medium hardness (compressive strength < 200 MPa), few impurities, and a relatively brittle texture, making it suitable for impact crushing.
Production Requirements: a. Applications where a high-fineness product is desired (e.g., manufactured sand production) or where cubic particles are required (e.g., commercial aggregate).
b. Applications where flexible particle size adjustment is required in small or medium-sized production lines (impact crushers can quickly change the output particle size by adjusting the gap between the impact plates). Additional Advantages: The crushing process inherently shapes the sand, reducing subsequent shaping steps and making it suitable for construction sand with high particle shape requirements.

3. Maintenance and Cost Comparison
Wear Part Life: Cone crushers’ wear parts are mostly made of manganese steel, which provides a longer lifespan when crushing hard rock. Impact crushers’ hammers and impact plates wear more quickly, requiring more frequent replacement, especially when processing hard limestone.
Maintenance Difficulty: Cone crushers have a more complex structure, requiring specialized tools for overhaul; impact crushers have a simpler structure, making component replacement easier.
Initial Investment: For the same specifications, cone crushers are slightly more expensive than impact crushers. However, in the long term, if the material hardness is too high, the maintenance cost of an impact crusher may exceed that of a cone crusher.
4. Overall Recommendation
When a cone crusher is preferred:
a. The limestone is hard, and the production line is large and operating stably over a long period of time.
b. The finished product is primarily used for applications such as road base and construction coarse aggregate, where particle shape requirements are less stringent but uniform particle size is required. Impact crushers are preferred in the following situations:
a. Limestone with medium hardness, requiring fine particle shape and a high concentration of fine powder (e.g., sand production).
b. Medium-sized production lines requiring flexible particle size adjustment or requiring finished product shaping.
When selecting a crusher, factors such as raw material particle size, moisture content, and production line layout (e.g., whether screening equipment is included) should also be considered. We recommend conducting on-site trials based on specific operating conditions to determine the optimal solution. For detailed equipment selection information or production line inspections, please contact Shengbang Machinery via WhatsApp at +8613949025317.