Tracked Impact Crusher For Sale

What Exactly is a Tracked Impact Crusher? What’s Its Main Role in a Mobile Crushing Plant?

A Tracked Impact Crusher is essentially an Impact Crusher (a machine that uses high-speed rotating blow bars to strike material, causing it to collide with impact plates and break) mounted on a tracked chassis, integrated with feeding, conveying, and power systems. In a mobile crushing and screening plant, it typically serves as secondary or tertiary crushing equipment, primarily responsible for material shaping and fine crushing, producing well-shaped (cubical) finished aggregates.

Compared to Tracked Jaw or Cone Crushers, What are the Unique Advantages and Limitations of a Tracked Impact Crusher?

The greatest advantages of a Tracked Impact Crusher are its excellent product shape (high cubical content) and relatively large reduction ratio (it can break material down significantly in a single pass). However, its limitation is its sensitivity to material hardness; when processing very hard or highly abrasive materials, wear parts like blow bars can wear out quickly, leading to higher operating costs.

Feature	Tracked Impact Crusher	Tracked Jaw Crusher	Tracked Cone Crusher
Primary Use	Secondary/tertiary crushing, shaping, processing medium-soft materials, C&D waste	Primary crushing (coarse), handles various hardness materials	Secondary/tertiary crushing, handles medium-hard to very hard materials
Product Shape	Excellent (cubical)	Fair (more angular)	Good (depends on chamber type)
Reduction Ratio	Large	Moderate	Moderate to Large
Material Hardness	Medium-soft to medium-hard (e.g., limestone, C&D waste)	All hardness levels (excels with hard rock)	Medium-hard to very hard (e.g., granite, basalt)
Wear Part Cost	Blow bars, impact plates wear relatively faster (Insight #2, #4)	Jaw plates wear relatively slower	Mantle & concave wear moderately
Investment Cost	Medium	Medium	Higher
Operating Cost	Medium for soft materials, higher for hard/abrasive materials	Relatively lower	Medium-high for hard materials

What materials are tracked impact crushers suitable for?

Limestone, dolomite, and other medium-soft materials, as well as complex construction waste, are ideal for Tracked Impact Crushers. It can crush and shape these materials to produce high-quality aggregates with extremely low flaky/elongated content, approaching perfect cubical shapes, which is highly beneficial for improving concrete strength and asphalt pavement quality.

• Limestone and other medium-soft rocks: The Tracked Impact Crusher can efficiently crush them. Since the material isn’t very hard, blow bar wear is relatively manageable. The crushed limestone aggregate is well-shaped and widely used in highways, railways, and concrete batching plants.
• Construction Waste (C&D Waste): Tracked Impact Crushers effectively process concrete blocks, bricks, and small amounts of asphalt. The impact crushing principle helps separate concrete from rebar (magnetic separation needed) while producing well-shaped recycled aggregates. However, pay attention to pre-processing to remove excessive large rebar and debris.

What factors affect the wear of blow bars in an impact crusher?

Compared to jaw plates in jaw crushers or liners in cone crushers, the blow bars in an impact crusher are indeed a core wear part that wears out relatively quickly. The lifespan of a set of blow bars varies greatly depending on material hardness, abrasiveness, feed size, operation, etc., ranging from tens to hundreds of hours. Replacement costs vary by blow bar material, size, and equipment brand, and are a major operating expense.

• Key Factors Affecting Blow Bar Life:
  • Material Hardness and Abrasiveness Index: This is the most critical factor. Crushing hard, high-SiO2 materials will drastically shorten blow bar life.
  • Blow Bar Material : High chromium cast iron (common), martensitic steel, manganese steel alloys, ceramic composites, etc. Different materials have different wear resistance and toughness, and also different prices. Choosing the material that best matches your feed material is crucial; the most expensive isn’t always the best.
  • Feed Size Control: Oversized feed will accelerate impact wear on blow bars.
  • Rotor Speed and Chamber Design: Affects impact force and material trajectory within the crushing chamber.
  • Operation and Maintenance: Timely adjustment of impact plate gaps, avoiding no-load running, etc.

What’s the Maximum Feed Size a Tracked Impact Crusher Can Accept? How Fine Can the Output Size Be Adjusted?

The maximum allowable feed size for a Tracked Impact Crusher typically ranges from tens to hundreds of millimeters, depending on the model. Its output size can be adjusted by changing the gap between the impact plates and blow bars, and sometimes rotor speed (on some models), generally adjustable from a few millimeters to tens of millimeters, meeting various finished aggregate specifications.

• Feed Size: Generally, the feed opening of a Tracked Impact Crusher is smaller than that of a Tracked Jaw Crusher because it mainly processes material that has already undergone primary crushing. For example, a Zoneding Tracked Impact Crusher ZDE1315 might have a maximum feed edge length of around 300-400mm. It’s crucial to ensure the feed doesn’t exceed the maximum allowed size to prevent damage to blow bars and the rotor.
• Output Adjustment:
  • Adjusting Impact Plate Gap: This is the primary method. A smaller gap results in finer output, but production may decrease, and blow bar wear might accelerate. Hydraulic adjustment is more convenient.
  • Adjusting Rotor Speed: Some high-end models allow rotor speed adjustment via a variable frequency drive. Higher speed means greater impact force, more fines in the product, and better shape; lower speed means less impact force, coarser product, and relatively slower blow bar wear.
  • Adding a Grinding Chamber (some models): Some impact crushers are designed with a third or even fourth impact plate (grinding chamber) to further reduce material size and produce finer products.

What is the Actual Processing Capacity (Throughput) of a Tracked Impact Crusher?

The actual throughput (tons/hour) of a Tracked Impact Crusher also varies by model, material characteristics, feed/output size settings, operator skill, etc., ranging from tens of tons for small units to hundreds of tons for large ones. Note that the “theoretical maximum capacity” stated by manufacturers is measured under ideal conditions; actual production usually reaches only 60%-80% of this value.

• Factors Affecting Actual Throughput :
  • Material Hardness, Moisture, Clay Content: Hard, wet, or clayey materials will reduce throughput.
  • Feed Size Distribution: Uniform, compliant feed is necessary for maximum efficiency. Too many fines or oversized lumps will hinder performance.
  • Required Output Size: The finer the required output, the lower the throughput.
  • Blow Bar Wear: As blow bars wear, crushing efficiency decreases, and so does throughput.
  • Feed Consistency and Uniformity: Stable, uniform feeding is a prerequisite for high output.

Does a Tracked Impact Crusher Generate a Lot of Dust During Operation? How Can It Be Effectively Controlled?

Because impact crushers use high-speed impact to break material, and material movement within the chamber is vigorous, they typically generate more dust than jaw or cone crushers. However, modern Tracked Impact Crushers are usually equipped with effective dust suppression systems.

• Reasons for Dust Generation: Material striking and rubbing at high speeds within the crushing chamber generates many fine particles.
• Effective Control Measures :
  • Water Spray Systems: Nozzles installed at the feed inlet, key points in the crushing chamber, and discharge conveyor spray atomized water to wet dust particles, causing them to settle. This is the most common and effective measure.
  • Sealed Design: The crushing chamber, conveyor connections, etc., should be designed to be as sealed as possible to reduce dust escape.
  • Dust Collectors (Optional): For some high-end equipment or specific environmental requirements, a negative pressure dust collection system can be added.
  • Pre-Wetting Material: If conditions allow, moderately spraying the material before it enters the crusher can also reduce subsequent dust.

Environmental protection is a trend. Choosing a Tracked Impact Crusher with good dust control design not only complies with regulations but also improves the working environment.

Besides Blow Bars, What Other Wear Parts on a Tracked Impact Crusher Need Frequent Attention and Replacement?

In addition to the fastest-wearing blow bars, other major wear parts on a Tracked Impact Crusher include impact plates (liners), side liners, and components like bearings and belts. These parts wear more slowly than blow bars but still require regular inspection and replacement as needed.

• Impact Plates (Liners): One of the main surfaces chịu đựng material impact, typically made of high manganese steel or wear-resistant alloy steel. Their wear affects product shape and crushing efficiency. Matching with blow bars is very important .
• Side Liners: Protect the sides of the crushing chamber body from wear, usually made of high manganese steel.
• Other Parts on the Rotor Body: Such as blow bar wedges or fixing blocks, which can also loosen or wear due to long-term impact.
• Bearings: The rotor spins at high speed, and bearings endure huge loads. They require regular lubrication and inspection and are critical components.
• Drive Belts: V-belts that drive the rotor will wear and age, requiring regular checks for tension and integrity.
• Conveyor Belts: The feed and discharge conveyor belts are also wear parts.

Establishing a detailed equipment maintenance plan and regularly inspecting these wear parts is key to ensuring the long-term stable operation of the Tracked Impact Crusher.

How Can a Tracked Impact Crusher Be Combined with a Mobile Screening Plant for Efficient Production?

For efficient production, a Tracked Impact Crusher is usually closely paired with a Tracked Mobile Screening Plant. The impact crusher handles crushing and shaping, while the screening plant grades the crushed material. The key is to ensure matching processing capacities, smooth material transfer, and potentially a closed-circuit setup to optimize product quality.

A typical combination:

1. Primary Crushing (Optional): Tracked Jaw Crusher (for large, hard rock) or direct excavator feeding (for smaller, medium-soft material or C&D waste).
2. Secondary/Shaping Crushing: Tracked Impact Crusher (Tracked Impact Crusher).
3. Screening and Grading: Tracked Mobile Screening Plant, to screen the impact crusher’s output into different-sized finished aggregates (e.g., 0-5mm, 5-10mm, 10-20mm).

Key Points for Efficient Synergy:

• Capacity Matching: The impact crusher’s throughput should match the screening plant’s processing capacity.
• Closed-Circuit Operation (Optional): Returning oversized material from the screen back to the impact crusher via a return conveyor can maximize the yield of qualified products and further optimize particle shape. Many tracked impact crushers have integrated return systems and small screens for some degree of closed-circuit operation.
• Material Conveying: Ensure smooth conveyor belt connections between units, with appropriate angles and speeds.
• Integrated Control : Advanced production lines can achieve inter-equipment linkage control and automatic load adjustment.

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FAQ

Q1. What exactly is a mobile crushing station used for? How is it better than a stationary production line?
A1: The biggest advantage of a mobile crushing station is its flexibility and convenience. It doesn’t require foundation work and can be quickly relocated or moved closer to the working face. For you, this means significant savings in civil engineering costs and time, enabling faster production startup. It also reduces the internal material transport distance on site, lowering transportation costs and dust. It’s particularly suitable for projects with tight schedules, scattered sites, or those requiring phased progression.

Q2. Crawler-type vs. tire-type mobile crushing station, which is more suitable for me?
A2: It mainly depends on your mobility needs and site conditions. Crawler-type is like a tank, suitable for moving within mines or rugged construction sites, offering flexible relocation but troublesome for long-distance transport; tire-type is like a trailer, suitable for projects with better road conditions that require frequent long-distance transfers across regions. Simply put, choose crawler for on-site flexibility, choose tire for long-distance transfers.

Q3. Mobile crushing stations have several main machine types (jaw crusher/impact crusher/cone crusher). How should I choose?
A3: Choose based on your material and output requirements. Mobile jaw crushers are suitable for primary crushing, handling large, hard materials; mobile impact crushers are suitable for processing medium-soft materials (like limestone, construction waste) and produce good particle shapes; mobile cone crushers are suitable for medium-fine crushing of hard rocks (like granite, river pebbles). Not sure? Tell us your raw materials and finished product needs, and we’ll help you configure the setup.

Q4. What capacity mobile crushing station do I need? How can I estimate reliably?
A4: The capacity stated by manufacturers is usually the “maximum capacity” under ideal conditions; actual output will be lower. You need to consider: What material needs processing (hardness)? What’s the feed size? How much soil/clay content? How fine does the output need to be? Provide this information to the supplier, and let them use their experience to help you choose a model with sufficient margin. Don’t just rely on paper figures.

Q5: Is maintaining a mobile crushing station troublesome? Is the fuel/power consumption high?
A5: Routine maintenance (lubrication, tightening, cleaning) isn’t complex, but hydraulic and electrical systems require some professional knowledge. Mobile stations have compact structures, so maintenance in some areas might be less convenient than stationary plants. Fuel/power consumption is a major operating cost, highly related to equipment power, load, and power system (diesel/electric/hybrid). Choosing a diesel-electric hybrid might save more money in the long run.

Q6: What if one mobile crushing station isn’t enough? Can they be combined into a production line?

A6:Absolutely! Mobile crushing stations are very suitable for combined use, forming a complete mobile crushing and screening production line. For example, use a mobile jaw crusher for primary coarse crushing, followed by a mobile impact crusher or mobile cone crusher for medium-fine crushing, and then add a mobile screening plant for sizing. This combination can meet complex production needs with extreme flexibility.

Q7: When selecting a mobile crushing station, what key points should I focus on besides price?
A7: Price is important, but definitely not the only criterion! Pay more attention to: 1. Quality of core components (main crusher, engine/motor, hydraulic system); 2. Match between actual output and working conditions; 3. Durability of structural parts (chassis, frame); 4. Cost-effectiveness and supply of wear parts; 5. Ease and safety of operation and maintenance; 6. Manufacturer’s after-sales service and technical support capabilities.