Not every rock crusher is right for every application. When choosing the best crusher for your aggregates application, it’s critical to understand the different mechanisms by which rock crushers work and the effect this has on efficiency, operation costs, and the final product. 

One of Sepro’s aggregate experts, Dave Phelan, explains in more detail in the video below. 

Impact vs Compression

Rock crushers are first categorized by the general crushing mechanism. Compression crushers include jaw crushers, cone crushers, gyratory crushers and roll crushers. Impact crushers include vertical shaft impactors or horizontal shaft impactors.

Compression crushers require much less maintenance; high impact crushers undergo more wear and tear due to the material colliding within the crusher. In contrast, compression crushers typically have lower maintenance costs overall due to less wear and tear. Compression crushing results in flatter output material whereas impact crushing creates a cubical material that may be higher quality for certain applications. 

Horizontal Shaft Impactor Applications

Horizontal shaft impact crushers are ideal as a small portable crusher. They produce a cubical product and allow for a significant reduction in a closed circuit to finish a product to a certain size. However, horizontal shaft impactors are not very efficient for creating a product below 1.5”; below 1”, wear costs increase significantly. Impact crushers are more typically used for:

  • Limestone quarries and other limestone based products
  • Asphalt recycling
  • Concrete recycling 
  • Small sand and gravel applications
  • Other preprocessed materials

Cone Crusher Applications

Cone crushers, a type of compression crusher, have less versatility than a horizontal impact crusher, but a great capability to guarantee a finished product size. If set at 2”, typically 80% of the final product will meet the 2” target which is not something that can be replicated by jaw crushers or impact crushers. Cone crushers have less reduction and are sensitive to contamination, however they’re the best finishing crusher to create a consistent, high quality product. Cone crushers are typically used for:

  • Secondary or tertiary crushing in hard rock and gravels
  • Pebble crushing in mining circuits
  • Production of construction aggregate materials

Learn More About Rock Crushers

With an array of different types, sizes, and purposes, choosing a rock crusher can quickly become overwhelming. Add in the fact that a significant investment is required to purchase a rock crusher and the decision becomes even tougher!

Speaking with an aggregate equipment expert like Dave Phelan can help you make the right choice the first time. Contact our team of aggregate experts when looking for your next rock crusher and other pieces of aggregate equipment.