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Choosing the right crusher based on ore characteristics hinges on matching the ore’s physical properties (hardness, brittleness, particle size), processing requirements (finished product particle size, output), and operating constraints (moisture content, mud content).
From the perspective of matching core ore characteristics with equipment:
1. Ore hardness (Mohs hardness): Determines the equipment’s wear resistance.
Hardness is the most critical indicator, directly impacting the life of the crusher’s wear parts and crushing efficiency. The higher the Mohs hardness, the more difficult the ore is to crush, requiring equipment with high wear resistance and strong compressive strength.
Hard rock (Mohs hardness ≥ 6): such as granite, iron ore, pebbles, and basalt.
Coarse crushing: Jaw crusher (a general-purpose coarse crushing equipment with a compressive strength of ≤320 MPa, capable of handling large ore (500-1000 mm) with stable efficiency). Secondary/Fine Crushing: Cone Crusher (Specialized for hard rock, uses the “laminated crushing” principle (inter-rock compression and crushing) to reduce wear on the equipment liner. Suitable for crushing 100-200mm materials to 20-50mm (secondary crushing) or 5-20mm (fine crushing, using a short-head cone crusher).
Features: High compressive strength (150-300MPa) and strong toughness, but causes significant wear during crushing.
Not Recommended: Impact Crusher (wear parts (hammers) have a very short lifespan in hard rock, requiring frequent replacement and poor economic efficiency).
Recommended Equipment:
Medium-hard rock (Mohs hardness 3-5): such as limestone, sandstone, marble, and dolomite.
Coarse Crushing: Jaw Crusher (same for hard rock, can process 300-800mm ore). Secondary/Fine Crushing: Impact crushers (use “impact crushing” (high-speed hammer impacting the ore) achieve high crushing efficiency (20%-30% higher than cone crushers), resulting in a fine-grained finished product (high cubic content, low flakes), suitable for direct production of aggregates for building materials). For high production volumes (≥500 t/h), cone crushers (for improved stability) are also an option.
Characteristics: Medium hardness, high brittleness, easy to break, and a relatively regular crushed particle shape.
Soft rock (Mohs hardness ≤ 2.5): such as gypsum, coal, shale, and talc.
Coarse Crushing: Small jaw crushers (capable of processing 200-500 mm ore, no larger size required). Secondary/Fine Crushing: Hammer crusher (simplified structure, uses high-speed rotating hammers to directly crush ore, resulting in a high crushing ratio (can reduce 300mm material to less than 20mm in one go), suitable for single-stage crushing); or impact crusher (better particle size, suitable for applications where the finished product appearance is important)).
Characteristics: Low hardness, extremely brittle, easy to crush, and may have a high water content (such as coal).
2. Ore Brittleness and Toughness: Influencing Crushing Method (Impact/Extrusion)
Highly brittle ores (such as limestone and glassy rock): have numerous internal cracks and easily break upon impact. They are suitable for impact crushing (impact crusher, hammer crusher), which offers high efficiency and good particle size.
Highly tough ores (such as iron ore and copper ore): are highly impact-resistant and require extrusion crushing (jaw crusher, cone crusher), which crushes by applying pressure slowly to avoid equipment overload. 3. Ore Particle Size and Output: Determine Equipment Specifications and Number of Crushing Stages
Large Ore Particle Size (≥500mm): Primary Crushing (jaw crusher) is required to reduce the particle size to 100-200mm before entering secondary crushing.
Small Ore Particle Size (≤200mm): Primary crushing can be skipped and secondary crushing (such as impact crusher or cone crusher) can be used directly.
High Production Requirement (≥1000t/h): Heavy equipment (such as CJ series jaw crusher + multi-cylinder cone crusher) is preferred, with capacity increased through parallel operation.
Low Production Requirement (≤100t/h): Light Equipment (such as PE series jaw crusher + small impact crusher) is recommended.
4. Finished Product Requirements (Particle Size and Shape): Determine Fine Crushing/Shaping Equipment
Coarse Finished Product Particle Size (20-50mm, such as roadbed aggregate): Secondary Crushing (cone crusher, impact crusher) can be used directly without fine crushing. For fine finished product particle size (0-5mm, such as manufactured sand), “fine crushing and shaping” are required. An impact sand maker is recommended. It uses a “rock-on-rock” mode (ore impacting each other) or a “rock-on-iron” mode (ore impacting a metal liner) to simultaneously crush and shape the material, reducing the flake content to ≤15%, meeting concrete sand standards.
For ore with no specific particle shape requirements (such as pre-beneficiation ore), cone crushers (wear-resistant, suitable for hard rock) or hammer crushers (high efficiency, suitable for soft rock) are preferred.
5. Special Characteristics (Moisture Content, Mud Content): Avoid Equipment Clogging
High moisture content (≥10%) or high mud content (≥5%): Ore is prone to agglomeration, potentially clogging the equipment’s feed and discharge ports. Recommended: Jaw crusher (large feed opening, less prone to clogging) + cone crusher (laminated crushing, adjustable gap, and anti-clogging);
Not recommended: Hammer crusher (grate screen easily clogged by wet mud) or impact crusher (small gap between hammer and liner, prone to wet material sticking).
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