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Understanding the Crushing Stages of a Crusher

Jun. 10, 2021

Understanding the crushing stages and the type of crusher best suited for each stage can simplify equipment selection. Each type of crusher is different and is used to achieve a specific end result. Similarly, it is expected that at the end of each crushing stage a certain throughput will be available for the next stage of the process. Aggregate producers who pair the right crusher with the right stage will be the most efficient and, in turn, the most profitable. Next, the crusher supplier will share the following content with you.


Crushing Stages

Most aggregate producers are well versed in crushing plant selection and know that equipment can be selected based on specification sheets and gradation calculations alone. Nevertheless, the theoretical conclusions must always be weighed against the material at hand and the practical experience with the operation, maintenance, and economics of the different solutions.

Usually, the material reduction is carried out in stages. There are some single crusher systems, but the most common systems involve at least two or three crushing stages.


Primary crushing

The primary task of the coarse crusher is to make it possible to transport the material on a conveyor belt. In most aggregate crushing plants, primary crushing is performed in a jaw crusher, although a rotary primary crusher can also be used. Impact crushers may also be the best choice if the material is easily crushed and not excessively worn.


The most important characteristics of a coarse crusher are capacity and the ability to accept raw material without clogging. Large primary crushers are more expensive to purchase than smaller machines. For this reason, the investment cost calculation for a primary crusher is weighed against the cost of blasting the raw material to a smaller size.


In most cases, trucks deliver the raw material to a fixed primary plant. The cost of fuel, tires, maintenance, and return on investment should also be considered. In cases where producers crush at the quarry, a pit-mounted portable coarse crusher may be an economically sound solution. In modern plants, it is often advantageous to use a portable primary crusher so that it can follow the movement of the work face from which the raw material is extracted.

Rotor Centrifugal Crusher

Rotor Centrifugal Crusher

Intermediate (secondary) crushing

The purpose of intermediate crushing is to produce a variety of coarser fractions or to prepare material for final crushing. If a medium crusher is used for railroad ballast, the quality of the product is important.

In other cases, there is usually no quality requirement, but the product must be suitable for fine crushing. In most cases, the goal is to obtain the greatest possible reduction at the lowest possible cost.


Fine (tertiary) crushing

In this crushing stage, the quality and quantity of the fine product are determined. The quality requirements of the final product can be very stringent, especially in the aggregate industry.


In most cases, the fine crushing and cubing functions are combined in one crushing stage. Selecting a crusher for tertiary crushing requires both practical experience and theoretical knowledge. This is where manufacturers should ensure that experienced application specialists are brought in to ensure that the system is designed correctly.


Rotor centrifugal crusher, abbreviated as impact crusher, commonly known as sand making machine, is a kind of high-energy and low-consumption impact crusher with an international advanced level. Its performance plays an irreplaceable role in various ore fine crushing equipment and is currently the best effective, practical, and reliable stone crushing machine. It is widely used in metal and non-metal ores, cement, refractory materials, abrasives, glass raw materials, construction materials, artificial sand making, river pebbles, mountain rocks, etc. If you want to get more information about the wholesale best crusher price, welcome to contact us.


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