Compound Crusher

What is Compound Crushers?

A compound crusher, also called vertical compound sand maker, is a double-rotor primary impact crusher. The compound crusher is an ideal machine for crushing high-moisture and viscous materials, commonly used in small-scale crushing and sand production lines.

A Compound Crusher is a type of crusher that combines multiple crushing mechanisms within a single machine. It typically uses a combination of impact and grinding forces to reduce materials to a fine size. Unlike simple crushers, it can achieve a high reduction ratio, meaning it can take relatively large feed sizes and produce very small output sizes in one step.

Why do you need a Compound Crusher?

A compound crusher offers several key advantages that make it a valuable asset for certain applications:

• High Reduction Ratio: It can reduce materials to a much smaller size than many other types of crushers in a single pass.
• Cubical Product Shape: The crushing action produces aggregates with a more cubical shape, which is highly desirable for concrete and asphalt production.
• Simple Structure, Easy Maintenance: The design is relatively simple, making it easier to maintain and repair compared to more complex crushing systems.
• Handles Wet Materials: Some compound crushers are designed to handle materials with a higher moisture content, which can be a significant advantage in certain environments.
• Cost-Effective: It combines multiple crushing stages into one machine, reducing the need for multiple pieces of equipment and lowering overall costs.

What are Advantages of Compound Crusher?

Compound crusher combines the advantages of impact crusher and hammer crusher, showing multiple highlights. Its features include:

• 1.This model has both primary and secondary crushing functions, which not only has high crushing efficiency but also has lower cost.
• 2.With large crushing ratio, it can refine the material of 100-240mm to small particles below 3-5mm at one time.
• 3.The gap between hammer head and impact plate can be flexibly adjusted to meet different particle size requirements.
• 4.Designed with gridless structure, so it is not easy to be clogged even when dealing with materials containing a large amount of slurry.
• 5.Long bearing life and horizontal arrangement enables it to handle high temperature materials such as cement clinker.
• 6.Low noise level of 75 decibels (dB) during operation and effective control of dust pollution.
• 7.The wearing parts are made of special alloy material, which combines high hardness, high toughness and multi-element alloy wear resistance, significantly extending the service life to 2-3 times of the original.
• 8.The rear chamber is equipped with a screw or hydraulic pressure opener, which greatly facilitates the replacement of wearing parts.

Components of Compound Crusher

The main components of a compound crusher include:

• Feeding Hopper: The inlet where material enters the crusher.
• Rotor with Hammers: The rotating part with hammers that provide the initial impact.
• Crushing Chamber: The internal space where crushing and grinding occur.
• Wear-Resistant Liners: Plates lining the crushing chamber to protect it from wear and tear.
• Discharge Opening: The outlet where the crushed material exits.
• Drive Motor: The motor that powers the rotor.

What is the Structure of Compund Crusher?

The vertical compound crusher is mainly composed of the crushing system (rotor, bearing, liner, hammer), transmission system (motor, pulley), in-and-out mouths, and other parts. Among them, the crushing system is the easy-wearing component, which is mainly introduced for you.

Compound Crusher Application

Compound Crusher has a wide range of applications and is commonly used for crushing medium-hard materials in middle or small-sized plants. Here are some specific applications:

Coal, limestone, granite, cobble, dolomite, bluestone, iron ore, coal gangue, activated carbon, quartz, basalt, slag, etc.

• Aggregate Production: Producing high-quality aggregates for concrete, asphalt, and road construction.
• Sand Making: Manufacturing artificial sand for construction and other applications.
• Mining: Crushing various ores and minerals to a fine size for further processing.
• Cement Production: Fine crushing of limestone and other raw materials for cement manufacturing.
• Construction Waste Recycling: Processing construction and demolition waste into usable aggregates.

Application of Compound Crusher

What Types of Rock and Ore Can a Compound Crusher Handle Effectively?

Compound crushers are best suited for materials that are moderately hard and not excessively abrasive. They can effectively handle a variety of rocks and ores, including:

• Limestone
• Dolomite
• Shale
• Gypsum
• Coal Gangue
• Various Non-Ferrous Ores

The Working Principle of Compound Crusher

The material in the upper part of the machine perpendicular drops into the high speed rotating impeller,and under the high speed centrifugal force, it produces high speed impact and comminution with the other part of the material which distributes in the shape of umbrella around the impeller vertical composite crusher. The impeller and the housing will be crushed by swirl impact and friction between the impeller and the housing for many times, which will be discharged directly from the bottom, forming a closed circuit multiple cycles, and controlled by the screening equipment to achieve the required product size.

How Does the Vertical Compound Crusher Work?

The Vertical Compound Crusher works using a combination of impact and grinding forces. Here’s a step-by-step breakdown:

1. Feeding: Material is fed into the crusher from the top.
2. Impact Crushing: The material falls onto a high-speed rotating impeller or rotor with hammers. The hammers strike the material with great force, shattering it into smaller pieces.
3. Grinding: The crushed material is then thrown against the inner walls of the crushing chamber, which are lined with wear-resistant plates. This causes further grinding and size reduction.
4. Discharge: The finely crushed material exits the crusher from the bottom.

When Should You Choose a Compound Crusher Over an Impact or Hammer Crusher?

The choice depends on your specific needs and material characteristics:

• Compound Crusher: Best for fine crushing, producing cubical shapes, and handling moderately hard materials. It is also suitable for wet materials.
• Impact Crusher: Ideal for secondary crushing of medium-hard materials, producing a good shape, but not as fine as a compound crusher.
• Hammer Crusher: Suitable for crushing softer materials like limestone and coal, with high reduction ratios, but not ideal for abrasive materials.

If you need very fine material with a good shape and are working with moderately hard rock, the compound crusher is the best choice.

What are Features of ZONEDING Compound Crusher?

ZONEDING compound crushers are designed with several features to ensure high performance and reliability:

• High-Quality Materials: Constructed with durable, wear-resistant materials for long service life.
• Optimized Rotor Design: The rotor is designed for efficient crushing and a consistent product size.
• Adjustable Crushing Chamber: Allows you to adjust the crushing parameters to meet your specific needs.
• Easy Maintenance: Designed for easy access to wear parts, simplifying maintenance and reducing downtime.
• Wet Material Handling: Capable of handling materials with higher moisture content without clogging.

ZONEDING’s Compound Crusher for Wet Material ensures consistent performance in challenging conditions.

How Much Price of Compound Crushers?

The price of a compound crusher can vary widely depending on its size, capacity, and features. Small to medium-sized crushers can range from $10,000 to $50,000, while larger, high-capacity crushers can cost upwards of $100,000. Contact ZONEDING for a customized quote based on your specific requirements.

What Determines the Production Capacity of Compound Crusher?

The production capacity of a compound crusher depends on several factors:

• Crusher Size: Larger crushers have higher capacities.
• Material Hardness: Softer materials can be crushed at a higher rate.
• Feed Size: Smaller feed sizes generally result in higher capacities.
• Moisture Content: Excessive moisture can reduce capacity.
• Rotor Speed: Higher rotor speeds can increase capacity but also increase wear.

How to Maintain Your Compound Crusher?

Proper maintenance is essential for the longevity and performance of your compound crusher:

• Regular Inspections: Check for wear and tear on hammers, liners, and other components.
• Lubrication: Follow the manufacturer’s lubrication schedule for bearings and other moving parts.
• Hammer Replacement: Replace worn hammers regularly to maintain crushing efficiency.
• Liner Replacement: Replace worn liners to protect the crushing chamber.
• Cleaning: Regularly clean the crushing chamber to prevent material buildup.

Why Choose ZONEDING?

Choosing ZONEDING means choosing quality, reliability, and expertise. With over 30 years of experience in manufacturing crushing equipment, we offer:

• Customized Solutions: We can tailor our crushers to meet your specific needs and material requirements.
• High-Quality Products: Our crushers are built with durable materials and advanced technology to ensure long-lasting performance.
• Competitive Pricing: As a factory-direct manufacturer, we offer competitive prices without compromising on quality.
• Excellent Service: We provide comprehensive support, from installation and training to maintenance and spare parts.

Our Limestone Fine Crusher is designed to maximize your production efficiency and product quality.

General Specification