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LATEST Crushers with High Crushing Ratio - Maximize Your Output

In the world of industrial processing, the ability to efficiently break down materials into smaller, more manageable sizes is of utmost importance. Crushers with a high crushing ratio have emerged as essential tools for achieving this goal, enabling businesses to maximize their output and enhance overall productivity. This article delves into the significance of high crushing ratio crushers, explores the various types available, and highlights their key advantages and applications.

Understanding Crushing Ratio

The crushing ratio is a fundamental parameter that defines the effectiveness of a crusher. It is calculated by dividing the size of the largest feed particle by the size of the smallest product particle. A high crushing ratio indicates that the crusher can reduce large pieces of material to much smaller sizes in a single pass, minimizing the need for multiple stages of crushing and subsequent processing.

For example, if a crusher can take in rocks with a maximum size of 100 mm and produce particles as small as 5 mm, the crushing ratio would be 100/5 = 20. Crushers with high crushing ratios, often ranging from 10 to 60 or even higher depending on the type and design, are highly sought-after in industries where fine or ultra-fine particle sizes are required.

Types of Crushers with High Crushing Ratio

Jaw Crushers

Jaw crushers are widely used in primary crushing applications and are known for their high crushing ratio. They feature a fixed jaw and a movable jaw that work in tandem to compress and break the material. The large feed opening allows for the handling of big rocks and ores. As the material is fed into the crushing chamber, the movable jaw exerts a powerful squeezing force, reducing the size of the particles. Some advanced jaw crushers can achieve crushing ratios of up to 8:1 or more, making them suitable for initial reduction of large chunks of material in mining, quarrying, and construction industries.

Cone Crushers

Cone crushers are secondary or tertiary crushers that excel in producing fine and uniformly sized particles. They are designed to handle materials with high hardness, such as granite, basalt, and various ores. The crushing action in a cone crusher occurs between a mantle (movable cone) and a bowl liner (fixed cone). As the mantle gyrates within the bowl liner, the material is subjected to a combination of compression and shear forces, resulting in a high crushing ratio. Cone crushers can typically achieve ratios ranging from 3:1 to 10:1, depending on the specific model and the setting of the crusher. Their ability to produce consistent product sizes makes them ideal for applications where high-quality aggregates for construction or further processing in the mining industry are required.

Impact Crushers

Impact crushers are highly effective in achieving high crushing ratios, especially for materials with medium hardness, like limestone, dolomite, and some types of coal. These crushers operate by using the impact energy of a rapidly rotating rotor equipped with hammers or blow bars. When the material enters the crusher, it is struck by the high-speed rotor, which throws the particles against the breaker plates or anvils located within the crushing chamber. This impact causes the material to break into smaller pieces. Impact crushers can achieve extremely high crushing ratios, often in the range of 20:1 to 50:1 or even higher. Their ability to produce a cubic-shaped product makes them popular in the production of high-quality aggregates for concrete and asphalt, as well as in recycling applications where materials need to be reduced to specific sizes.

Hammer Crushers

Hammer crushers are designed to handle a variety of materials, including those with a high moisture content such as coal and clay. They feature a rotor with hammers that rotate at high speeds. As the material enters the crusher, it is struck by the hammers, which break it into smaller fragments. Hammer crushers are known for their high reduction ratio, which can be as high as 10:1 to 20:1 in some cases. Their relatively simple design and low power consumption make them suitable for use in mining operations, power plants, and other industries where large volumes of materials need to be crushed efficiently.

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Advantages of High Crushing Ratio Crushers

Increased Productivity

High crushing ratio crushers enable businesses to process larger volumes of material in less time. With the ability to reduce the size of particles significantly in a single pass, fewer crushing stages are required, leading to a more streamlined production process. This not only saves time but also increases the overall throughput of the operation, allowing companies to meet higher production demands and potentially increase their market share.

Cost Savings

By minimizing the need for multiple crushing stages, high crushing ratio crushers can help reduce operational costs. Fewer crushers mean lower energy consumption, less wear and tear on equipment, and reduced maintenance requirements. Additionally, the reduction in the number of processing steps can lead to savings in labor costs and the cost of downstream processing equipment. For example, in a mining operation, if a high crushing ratio crusher can produce a product that is close to the final desired size, it can eliminate the need for additional grinding or re-crushing operations, resulting in substantial cost savings over the long term.

Better Quality Product

Crushers with high crushing ratios are often capable of producing a more uniform and consistent product size. This is particularly important in industries such as construction, where the quality of aggregates directly affects the strength and durability of concrete and asphalt. A high-quality product with a narrow particle size distribution can lead to better performance in downstream applications, reducing the risk of defects and ensuring a more reliable end product. In addition, the ability to produce fine or ultra-fine particles can open up new opportunities for businesses in industries such as pharmaceuticals, ceramics, and advanced materials, where precise particle sizes are crucial for product functionality.

Applications of High Crushing Ratio Crushers

Mining

In the mining industry, high crushing ratio crushers play a vital role in the extraction and processing of ores. They are used to break down large chunks of rock and ore into smaller sizes suitable for further beneficiation processes such as grinding, flotation, and leaching. Whether it's extracting valuable metals from copper, gold, or iron ores, or processing non-metallic minerals like limestone and quartz, crushers with high crushing ratios help improve the efficiency of ore processing, increase the recovery of valuable minerals, and reduce the overall cost of production.

Construction

The construction industry relies heavily on high-quality aggregates for the production of concrete, asphalt, and other building materials. Crushers with high crushing ratios are used to produce aggregates with the right size and shape characteristics. For example, in the production of concrete for high-rise buildings or infrastructure projects, the use of well-crushed aggregates can enhance the strength and workability of the concrete. Additionally, in road construction, high crushing ratio crushers are used to produce aggregates that meet the strict requirements for asphalt mixtures, ensuring the durability and performance of the roads.

Recycling

With the increasing emphasis on environmental sustainability, recycling has become an important industry. High crushing ratio crushers are used to break down a variety of waste materials, such as concrete, asphalt, and metal scraps, into smaller pieces for recycling and reuse. By reducing the size of these materials, crushers make it easier to separate and process different components, increasing the efficiency of the recycling process. For example, in a concrete recycling plant, crushers can break down old concrete slabs into smaller aggregates that can be used as a substitute for natural aggregates in new concrete production, reducing the demand for virgin materials and minimizing the environmental impact of construction activities.

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Previous News

29/8/2024

29/8/2024

Welcomes the Malaysian Minister of Works at MBAM OneBuild 2024

We are thrilled to announce that the Malaysian Minister of Works is visiting the Liming's booth (Booth No.: D07) at the MBAM OneBuild 2024 exhibition, held from August 28th to 30th. This prestigious event is a significant milestone for our company as we showcase our cutting-edge crushing and screening equipment, designed to revolutionize the construction industry.

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Liming has long been at the forefront of innovation, providing high-quality machinery that meets the evolving demands of the global market. Our participation in MBAM OneBuild 2024 underscores our commitment to strengthening ties with Malaysia’s construction sector and contributing to the nation’s infrastructure development.


We invite all attendees to visit us at Booth No.: D07 to explore our latest products and engage in meaningful discussions about the future of construction technology.

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Join us at MBAM OneBuild 2024 and discover how Liming is shaping the future of construction.


31/7/2024

31/7/2024

200 tph iron ore crushing project

The project is equipped with C6X jaw crusher, HST single-cylinder cone crusher, HPT multi-cylinder cone crusher, etc., with an output of 200 tons per hour and an output finished product specification of 8mm.

The finished product will be used for important railway steel, automobile steel, home appliance steel, special steel, etc., helping China's high-speed rail run at "world speed" and contributing to the construction of a beautiful China.


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25/7/2024

25/7/2024

Upgrading low-grade gold ore with 2000 TPD Capacity

Raw material: gold ore
Product size: 200 mesh
Work time: 24h(2 shifts)
Ore density: 3.8t/m³
Capacity: 2000t/d
Final grade: 8g/t


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This  is one gold ore upgrading project. If you have any ore mining project , free to consult on line for solutions.


11/7/2024

11/7/2024

EPCO Solutions for Aggregate and Mining Crushing

EPCO stands for Plan-Design-Purchase-Build-Maintenance-Operations. It is a holistic approach to managing projects in the aggregate and mining sectors. This method integrates every phase of the project lifecycle, ensuring that all aspects are covered comprehensively and seamlessly.

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If you need further assistance with your project or are interested in learning more about EPCO service packages, feel free to reach out for a consultation. Our team of experts is ready to help you achieve your project goals with efficiency and excellence.


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5/7/2024

5/7/2024

Mobile Quartz Stone Crushing

In the construction and mining industries, the demand for high-quality materials is ever-increasing. Mobile quartz stone crushing has emerged as a game-changer, providing an efficient and flexible solution for processing quartz into valuable aggregates. This innovative technology combines mobility with powerful crushing capabilities, making it an essential tool for modern construction projects.

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Key Features of Mobile Quartz Stone Crushers

Advanced Crushing Technology: Equipped with modern technology, these crushers ensure efficient and effective crushing of quartz stones.

Portability: Designed for easy mobility, these units can be quickly moved to different locations, providing unmatched flexibility for various projects.

Robust Construction: Built to withstand the rigors of heavy-duty crushing, mobile quartz stone crushers are durable and reliable.

User-Friendly Operation: With intuitive controls and automation, these crushers are easy to operate, even for those with minimal experience.


Applications of Mobile Quartz Stone Crushing

Construction Aggregates: Producing high-quality aggregates for use in concrete, asphalt, and other construction materials.

Mining Operations: Efficiently processing quartz extracted from mines into usable products.

Landscaping: Creating decorative stones and gravel for landscaping projects.

Road Construction: Providing essential materials for road base and paving.

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Get Quotation by leaving your requirements below!


28/6/2024

28/6/2024

Annual production of 1.2 million tons of construction sand and gravel

Recently, the technical upgrading of the "1.2 million tons of construction sand and gravel per year" production line has officially entered the final stage. In the technical upgrading workshop, the orderly arranged production lines are running at high speed. The technical upgrading engineers are checking the various operating links in an orderly manner on the central control platform. The production line is completed in one go from feeding, crushing, screening, shaping to finished products.

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Through this technical upgrading, the company's production capacity has been increased from 300 tons/hour to 500 tons/hour. In addition to reducing energy consumption costs, the quality control of sand and gravel has been greatly improved, especially in terms of important indicators such as particle grading, mud content, fineness modulus, crushing value, and methylene blue value, which better meet customer needs and lay an important foundation for further expanding the sand and gravel sales market.


15/5/2024

15/5/2024

Differences Between CIL and CIP Gold Extraction

Carbon In Leach (CIL) and Carbon In Pulp (CIP) are two commonly used methods in the gold extraction process. Although both methods involve the use of activated carbon to adsorb gold, there are significant differences in their operation processes, equipment layout, and application conditions. This article will explore the differences between CIL and CIP, highlighting their respective advantages, disadvantages.

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1. Basic Principles

1.1 Carbon In Leach (CIL)

The Carbon In Leach (CIL) process involves adding activated carbon directly into the leaching tanks where both leaching and adsorption occur simultaneously. The CIL process includes the following steps:

  • Crushing and grinding the gold ore into a pulp.

  • Mixing the pulp with sodium cyanide solution to dissolve the gold into a cyanide complex.

  • Adding activated carbon to the pulp during the leaching process, where the activated carbon adsorbs the dissolved gold.

  • After leaching and adsorption, the pulp undergoes solid-liquid separation to recover the gold-laden activated carbon.

  • The gold-laden activated carbon undergoes desorption and electrolysis to recover the gold.

1.2 Carbon In Pulp (CIP)

  • The Carbon In Pulp (CIP) process differs primarily in the timing of adding activated carbon. The CIP process includes:

  • Crushing and grinding the gold ore into a pulp.

  • Mixing the pulp with sodium cyanide solution to dissolve the gold into a cyanide complex.

  • After leaching, transferring the pulp to a series of adsorption tanks where activated carbon is sequentially added to adsorb the dissolved gold.

  • After adsorption, the pulp undergoes solid-liquid separation to recover the gold-laden activated carbon.

  • The gold-laden activated carbon undergoes desorption and electrolysis to recover the gold.

2. Main Differences

2.1 Process Differences

Simultaneous Leaching and Adsorption: In CIL, leaching and adsorption occur simultaneously in the same step, whereas in CIP, leaching occurs first, followed by adsorption.

Process Complexity: CIP has a relatively simpler process because leaching and adsorption are separate steps. CIL requires more precise control of process parameters as leaching and adsorption occur concurrently, making it more complex to operate.

2.2 Equipment Configuration

CIL: Since leaching and adsorption occur in the same tank, CIL requires fewer tanks, but each tank is larger and more complex in design.

CIP: CIP requires separate leaching and adsorption tanks. Although there are more tanks, each tank is simpler in design and offers greater operational flexibility.

2.3 Gold Ore Characteristics

Ore Type Suitability: CIL is more suitable for low-grade, high-clay-content ores as these ores can clog the leaching tanks during processing. CIL’s design can better handle this issue. CIP is more suitable for high-grade, uniformly sized ores.

Pulp Handling Capacity: CIL requires stricter control over pulp concentration and particle size, while CIP is relatively more forgiving.

3. Advantages and Disadvantages

3.1 CIL Advantages and Disadvantages

Advantages:

Simultaneous leaching and adsorption result in a shorter process with faster reaction times.

Better suited for high-clay-content ores.

Disadvantages:

Requires precise control of leaching and adsorption process parameters, making it complex to operate.

Higher initial investment due to more demanding equipment and process design.

3.2 CIP Advantages and Disadvantages

Advantages:

Simple process with high operational flexibility.

Adsorption tanks can be used in series, improving adsorption efficiency.

Suitable for high-grade gold ores with simpler process control.

Disadvantages:

Requires separate leaching and adsorption tanks, occupying more space.

Less effective for high-clay-content ores.


The determination of the gold ore extraction process requires strict extraction tests and is determined by professionals. If you have any gold ore extraction needs, please leave a message below, one engineer from our team will contact you shortly.




2/5/2024

2/5/2024

New C6X series jaw crusher machine for sale in South Africa

Hot C6X series jaw crusher coming!We have a big discount in south aferica. Check the machine data below.


Features:

 Detachable and non-welded structure rack: The rack adopts separate design of side walls, front and rear walls, and is bolted and fixed.

 Replace the welding frame to avoid welding defects;

 Integrated motor base: saves about 15% of installation space; separate design

 Optimize the crushing chamber structure: the actual feed size increases and the crushing efficiency improves;

 Elastic limit shock absorbing device.

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Single unit output:

 The production capacity of a single machine varies depending on the machine model, with a minimum output of 80-290 t/h and a maximum output of 610-1510 t/h.

 500tph river stone EPC crushing project in Lhasa, China

 

Application: commercial concrete mixing station

Processed material: river stone            Capacity: 500T/H

Output size: 0-5mm, 5-13mm, 13-25mm, 25-31.5mm

Equipment: F5X1860 vibrating feeder, C6X145 jaw crusher, 2 sets of HST315 cone crusher, 2YK3X3075 vibrating screen, S5X2760-2 vibrating screen, 3 sets of S5X2760-3 vibrating screen, VSI6X1263 sand making machine, 2 sets of TX-36-45 fine sand recovery device, sewage system, 2 sets of dust collector


Get the favourable prices by leaving your requirements at the bottom of the site or online Chat.


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