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Replacing a Jaw & Cone Crusher Setup by a Mobile Impact Crusher Improves Material Quality & Total Operating Costs

Impact crushers can be used in many rock crushing application in lieu of a jaw and impact crusher. Applications include limestone, granite, and basalt.

Improve aggregate quality

Cuboid aggregate shape. Adjustable gradation. Meet your spec.

Lower operating cost

Operating one machine reduces maintenance, fuel, and transport costs.

Less complexity

Keep crushing with a straightforward process.

If you use jaw and cone crusher setups in low to medium abrasive rock applications you...


  • face extra fuel burn eating away at your profits
  • waste time maintaining 2 machines
  • face higher skilled labor requirements
  • invest more into spare parts to keep both machines running

 

Impact Crushers Process Soft- to Medium Hard Rocks Without a Primary Crusher

A common misperception is that impact crushers struggle with hard rock and in primary crushing applications. This is far from the truth. This article clarifies what applications can be done by mobile impact crushers instead of traditional jaw and cone crusher setups.

Abrasiveness, feed size, and material hardness are the 3 main determinants if you can use an impact crusher over a jaw and cone crusher train.

  • Abrasiveness describes the property of the rock that causes wear by friction. Silica content in your rock is a driver for material abrasivness.
  • Feed size describes the largest input piece dimension diameter.
  • Material hardness has a significant affect on crusher performance it doesn't exclude an impact crusher from processing hard rock. The harder to rock gets the smaller the feed size needs to be to avoid damages. Besides material hardness the break resistance is also important. In other words, material can be hard but still break easily.

 

Everybody talks about wear but nobody about the reduction ratio

Inexperienced salesmen put forward impact crusher wear costs which are higher than for compression based jaw and cone crushers. The statement without context is true but omits one essential fact: an impact crusher works harder to downsize material. In other words, an impact crusher can reduce the material significantly more than a jaw and cone crusher. The ratio of input size vs the output size describes the so-called reduction ratio.

Common reduction ratios and feed size example:

Reduction ratio example: jaw, cone, impactor
  Maximum reduction ratio Feed material Output size
Jaw crusher 6:1 24" 4"
Impact crusher 24:1 24" 1"
Cone crusher 5:1 4" 0.8"

 

10 reasons to replace your jaw and cone crusher setup with a mobile impact crusher

 

If your application permits to use an impact crusher over a jaw and cone crusher setup there are numerous reasons that support the use of an impact crusher.

  1. Less fuel burn: Only one machine burns fuel. For example, if you can save 8 gal / h in fuel over 1,500 hours a year at an average fuel cost of $4.50 per gallon this equates
    a saving potential of $54,000 in fuel.
  2. Less maintenance costs: Less fluids and fewer grease points, conveyor belts, and filters to maintain.
  3. Faster start-up and shut-down procedure: Simple and efficient procedure. Less risk to get the start-up procedure wrong. Less downtime during a blockage. For example, if your mobile impact crusher produces 300 tons per hour and saves you 30 min every day you can produce an additional 150 tons per day. Assuming you produce 150 days a year this adds up to an additional 22,500 tons of material.
  4. Lower parts inventory: Instead of stocking parts for a jaw and cone crusher you can reduce your parts inventory to what is needed to operate a single impact crusher.
  5. Lower moving costs: Cutting your equipment transport costs in half improves your bottom line.
  6. Easier setup: Setting up a jaw and cone crusher and an additional screening plant is time consuming and need to be tuned in before you can start crushing. Jack-knifing a screening plant for a closed-circuit operation adds an additional challenge.
  7. Improved material quality: Produce quality cuboid material. More chips and fine production.
  8. Increased versatility: a mobile impact crusher allows you to venture into different application such as on-site concrete recycling or producing roadbase with just a closed-circuit mobile impact crusher instead of a crusher and a separate screening plant.
  9. Lower training effort: Trust your guys around the machine because they need to handle only one type of machine.
  10. Lower risk for downtime: If one machine is down your entire crew is down. Using a single impact crusher reduces the number of moving parts in your processing operation that can go wrong, so that you reduce the risk for downtime and increase profits.

 

 

 

 

 

The right application for jaw and cone crusher trains

 

This article is not meant to bash against the traditional jaw and cone crusher setups. There is the right tool for every application. Jaw and cone crusher trains have been extremely successful in hard and abrasive rock applications with large infeed sizes. Whenever you need a jaw crusher that takes the brunt of the initial reduction in size, impact crushers would not be an option. Also if material quality is not an issue, you might want to consider a jaw and cone crusher over an impact crusher.

 

Crushing Rock Economically with One Crushing Stage Only

Replacing a jaw & cone crusher setup “The quality and efficiency were simply amazing”, reports Ing. Juan G. Vazquez, owner. “Previously, the cone crusher material was often rejected because it did not meet quality requirements. Now our material can be used for asphalt products without any problems.”
Crushing blast granite with 80% silicate "For rental jobs our machines are confronted with a wide range of feed materials such as reinforced concrete and granite. Regardless of the material – RUBBLE MASTER impact crushers always manage the job reliably at a high throughput”, says Tabo Verna, the owner of Fenomix, Argentina.
Crushing limestone with ease in Italy Processing limestone with a feed size of up to 27" (700 mm) producing a screened 2"- (50mm-) roadbase material in a single pass.
Mobile Impact Crushers Ideal for processing soft to medium-hard rock such as limestone, basalt, shale, granite, and sand & gravel.
 
 
Capacity
Inlet opening
Transport dimension
Weight
 
RM 120X
Impact Crusher
350 tph 385 TPH
1,160 x 820 mm 46" x 32"
16,180 x 2,990 x 3,600 mm 52‘10” x 9`11” x 10’6“
44,000 kg 95,000 lbs
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RM 100GO! Compact Crusher RM 100GO!
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33,600 kg 74,500 lbs
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RM 90GO! Compact Crusher RM 90GO!
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180 tph 200 TPH
860 x 650 mm 34" x 25"
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RM 70GO! Compact Crusher RM 70GO! 2.0
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