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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

25/4/2024

25/4/2024

The difference between NK and MK series portable crushing plant

The mobile crusher can be put into production in a short time, and the production line is more integrated when the space is limited. You can also flexibly change production sites.

The followings are two types of mobile crushers that we supply.

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NK Mobile CrusherMK Mobile Crusher

1. The frames are different.

2. The electrical control cabinet is different.

3. The configuration plans are different. NK focuses on small and medium-sized production lines (100-500 t/h), while MK focuses on medium and large-sized production lines (up to 800 t/h).

4. The finished belt configurations are different.


Leave your message below for the technical data and quotes!

24/4/2024

24/4/2024

Liming Showcase Innovations at MiningWorld Russia 2024

MiningWorld Russia is an internationally recognized exhibition dedicated to the mining and extractive industries. As a business platform, the exhibition brings together equipment and technology manufacturers with buyers from Russian mining companies, mineral processors and wholesalers interested in purchasing the latest solutions for the mining industry.

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Liming will take part in the MiningWorld Russia 2024 exhibition with our newest stone crushers and mills. Welcome to our booth to find out more details!


Date: April 23-25, 2024

Booth No.: C1009

Venue: Crocus Expo IEC, Pavilion 1, Hall 3, Moscow


12/3/2024

12/3/2024

With New Investment, Iron Ore Processing Project Marks a Breakthrough

Recently, it has been reported that Guinea's Simandou iron ore project has successfully secured a $15 billion financing, sparking widespread attention in the global mining industry. As manufacturers of iron ore processing equipment, we are filled with confidence and see tremendous development opportunities in this.

The Simandou iron ore project has long been under the spotlight due to its abundant resource reserves and potential development value. The successful financing of this project will inject new momentum into the mining industry in Guinea and the entire region. As suppliers of processing equipment, we will actively participate, providing high-quality processing equipment and comprehensive technical support to the project.

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The arrival of this investment signifies a new round of development opportunities for the iron ore processing industry. We will increase research and development investment, continuously improve the intelligence and automation level of equipment to meet the project's demand for efficient production and energy conservation. Additionally, we will enhance cooperation with the project stakeholders, offering customized solutions to tailor the most suitable production line, maximizing the value of resources.

The vigorous development of the iron ore processing project will drive the prosperity of the entire industry chain. Besides equipment provision, we will also actively engage in technical training and after-sales services, assisting the project stakeholders in enhancing production efficiency, reducing operating costs, and achieving sustainable development.

As manufacturers of iron ore processing equipment, we will continue to keep pace with the project's development, innovate continuously, and provide customers with higher-quality products and services, jointly creating a bright future for the iron ore processing industry.

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29/3/2023

29/3/2023

Heap leaching gold extraction process

[Process introduction] : Gold heap leaching process is to break low-grade gold ore to a certain particle size (or granulation), pile it on a leakproof bottom mat made of asphalt, concrete or plastic materials, spray with low-concentration cyanide, alkaline solution, non-toxic solvent or dilute sulfuric acid and other solutions on the mine heap to dissolve gold, and the gold-containing solution percolates out from the mine heap. Then the gold is recovered by activated carbon adsorption or zinc powder replacement precipitation.

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[Application field] : Gold heap leaching is often used to develop small ore bodies or low-grade gold deposits, or both, and cannot be exploited by conventional methods.

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18/3/2024

18/3/2024

Explore crushing and milling Opportunities at Our Booth - Spring Canton Fair Invitation

Dear customers,


We are thrilled to extend a cordial invitation to you and your esteemed team to visit our booth at the upcoming Spring Canton Fair, scheduled to commence in mid-April.

As one of the premier events in the realm of international trade, the Spring Canton Fair provides a dynamic platform for businesses to showcase their products, foster connections, and explore new opportunities. We are excited to be part of this prestigious event, and we would be honored to have you join us.

We will bring our new crushing and grinding machine with us there. Our team of experts will be on hand to provide insights, answer queries, and discuss potential collaborations. Whether you are interested in exploring new business opportunities, learning about our latest offerings, or simply networking with industry peers, we guarantee a valuable and enriching experience.

Here are the details of our booth:

Booth Number: Processing machinery and equipment exhibition area, exhibition hall 20.1, booth number K07

Location:  No. 382, Yuejiang Middle Road, Haizhu District, Guangzhou, China

Time :April 15-19, 2024

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To ensure that we can provie you with personalized attention during your visit, we encourage you to schedule a meeting with us in advance. Please feel free to contact online help to arrange a convenient time.


We genuinely look forward to welcoming you to our booth and engaging in meaningful discussions that can pave the way for mutually beneficial partnerships and collaborations.We eagerly anticipate the opportunity to connect with you at the Spring Canton Fair.


Warm regards,

Liming Team

7/3/2024

7/3/2024

1200 tons of Henan's new green building materials production line

The project covers an area of 840 acres, has an ore reserve of more than 50 million tons, and a designed annual output of 5 million tons.

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Processing materials: granite

Production capacity: 1200T/H

Finished product particle size: 0-5mm, 5-10mm

                 10-16mm, 16-33mm

Equipment configuration: 2 C6X jaw crushers

                 2 HST single-cylinder hydraulic cone crushers

                 4 HPT hydraulic cone crushers

                 12 sets of S5X series circular vibrating screens

The EPC project team is deeply involved in the management of the project construction process throughout the entire process, and strictly implements scientific measures of mining and greening at the same time. The entire production line meets the requirements for modular, industrialized, park-based, intelligent, and green production.


22/2/2024

22/2/2024

Optimizing Material Processing with Mobile Crushers: Tips and Techniques

Unlock the full potential of your mobile crushers with these expert tips and techniques for optimizing material processing efficiency:

  1. Preventive Maintenance: Implement a proactive maintenance schedule to keep your mobile crusher in top condition. Regular inspections, lubrication, and component replacements can prevent costly downtime and ensure optimal performance.

  2. Proper Setup and Calibration: Ensure proper setup and calibration of your mobile crusher for efficient material processing. Adjustments to settings such as crusher speed, conveyor height, and feed rate can significantly impact throughput and product quality.

  3. Material Selection and Preparation: Choose the right material for your application and ensure proper preparation before feeding it into the crusher. Remove contaminants, segregate oversized materials, and control the feed rate to optimize crushing efficiency and minimize wear on equipment.

  4. Optimized Crushing Chamber: Adjust the crusher's chamber settings to suit the characteristics of the processed material. Experiment with different settings to achieve the desired particle size distribution while maximizing throughput and minimizing energy consumption.

  5. Monitoring and Control Systems: Utilize advanced monitoring and control systems to track key performance indicators in real-time. Monitor parameters such as crusher load, feed rate, and product size distribution to identify potential bottlenecks and optimize crusher operation accordingly.

  6. Material Handling and Conveyor Systems: Streamline material handling processes and optimize conveyor systems to minimize downtime and maximize throughput. Proper belt tensioning, alignment, and maintenance are essential for smooth operation and efficient material flow.

  7. Dust Suppression and Environmental Controls: Implement effective dust suppression measures and environmental controls to ensure compliance with regulatory requirements and maintain a safe working environment. Dust suppression systems, enclosure designs, and ventilation strategies can minimize dust emissions and improve operator safety.

  8. Training and Education: Invest in comprehensive training programs for operators and maintenance personnel to ensure proper equipment operation and maintenance practices. Well-trained staff can identify potential issues early, troubleshoot problems effectively, and optimize crusher performance for maximum productivity.

  9. Continuous Improvement: Foster a culture of continuous improvement by regularly reviewing and analyzing crusher performance data. Identify areas for optimization, implement corrective actions, and monitor the impact on overall efficiency to drive continuous improvement initiatives.

  10. Collaboration with Suppliers: Work closely with equipment suppliers and industry experts to stay informed about the latest developments and best practices in mobile crusher technology. Collaborate on equipment selection, optimization strategies, and performance improvement initiatives to achieve mutual success.

  11. 250tph nickel ore mobile crushing line in New Caledonia

By implementing these tips and techniques, you can optimize material processing with your mobile crushers, improve productivity, and maximize return on investment in your crushing operations.


24/2/2024

24/2/2024

Comparing Jaw Crushers: Which Model Is Right for You

Are you in the market for a jaw crusher but unsure which model suits your needs best? This comprehensive guide breaks down the key factors to consider when comparing different jaw crusher models, helping you make an informed decision.

  1. Performance Metrics: Compare factors such as maximum feed size, capacity, and reduction ratio across various models to assess their performance capabilities.

  2. Operating Costs: Evaluate the energy consumption, maintenance requirements, and wear parts costs associated with each jaw crusher model to determine the most cost-effective option over its lifespan.

  3. Technology and Features: Investigate the innovative features and technologies integrated into each model, such as hydraulic adjustment systems, anti-friction bearings, and automated settings, to understand their impact on performance and productivity.

  4. Application Suitability: Consider the specific materials and applications for which each jaw crusher model is designed. Some crushers may excel in the primary crushing of hard rock, while others are optimized for the secondary or tertiary crushing of softer materials.

  5. Size and Mobility: Determine whether a stationary or mobile jaw crusher better suits your operational requirements. Mobile crushers offer flexibility and maneuverability, while stationary crushers may provide higher production capacities and stability.

  6. Environmental Considerations: Assess the environmental implications of each jaw crusher model, including noise levels, dust generation, and emissions, to ensure compliance with regulatory standards and minimize environmental impact.

  7. User-Friendly Design: Look for user-friendly features such as easy access to maintenance points, intuitive control systems, and safety enhancements to enhance operator convenience and safety.

  8. Customer Support and Service: Research the reputation of the manufacturer or supplier, including their after-sales support, spare parts availability, and service network, to ensure ongoing reliability and support throughout the lifespan of your jaw crusher.

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By carefully comparing these factors across different jaw crusher models, you can confidently select the model that best aligns with your operational requirements, budget constraints, and long-term goals. Remember to prioritize reliability, performance, and efficiency to maximize the return on your investment in a jaw crusher.


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