Crusher Philippines: The Unsung Hero among Equipment
When watching renovation shows, the cast would often mention big machines like excavators, bulldozers, and cranes. But, have you ever heard of the equipment called “crushers?”
Among all of the big equipment, the crushers in the Philippines are the least known by the common people.
A person is more likely to be familiar with forklifts, loaders, and scrapers. Little do Filipinos know that out of all the equipment and types of machinery, the crushers in the Philippines are an extremely useful and versatile machine.
If you want to know more about this all-around contraption, then read on!
Here, you will discover its origins and early form. You will also learn the different classification and application in different industries.
Basically, you will learn why crushers in the Philippines are extremely under hyped equipment.
The History of Crushers
Similar to most contraptions, the crusher also has its origins and even modifications through time.
In its early form around 2000 BC, a crusher was just a simple tool called “ball and socket” in reference to its appearance.
Fast forward a couple of centuries, around 4th century BC, the Chulimo named mill started utilizing a continuous crushing equipment.
However, the modern crushing machine was devised after the emergence and furtherance of the steam engine and electric motors. A roll crusher that was powered by a steam engine was first used in 1806.
Another prototype emerged in 1840 which utilized iron knobs or hammers that were secured on a cylindrical drum made of wood. The concept of this model was crushing the rocks as the cylindrical drum revolves at about 350 RPM.
In 1858, Eli Whitney Blake pioneered the first mechanical rock breaker and patented it as the “Blake Jaw Crusher.” His model utilized the concept of a powerful toggle linkage. Up until today, the Blake Jaw Crusher is the standard being used in judging crushers.
Between 1860 and 1878, the Gyratory Principle was patented as a basis for crusher designs. The crushing process was deemed impractical, thus disregarded.
The Gyratory Principle was given a modern design in 1881 by W. Gates. This model saw success with the reproduction of thousands of the model.
A contest between a Blake Jaw Crusher and a Gates Gyratory Crusher was then executed. During the contest, both crushers have the same rock size and discharge settings. By finishing the work in just 21 minutes, the Gates crusher won, while the Blake crusher completed in 65 minutes.
The first ever cone crusher was designed primarily by the Symons brothers, this led to domestic manufacturers naming them. During 1920, their crusher was utilized in crushing mills.
Rocks that was crushed down to granule and uniform size started to be manufactured as the hydraulic stone crusher was constructed in 1948.
The hydraulic stone crusher was re-designed due to the rise of technical advancement. In 1970, this model of crusher was equipped with an automatic controller for better management.
What are the Different Types of Crushers?
There are 2 main kinds of crushers: Primary Crushes and Secondary Crushers. These two main types are categorized by the size of materials they can manage to break down.
Primary crushers that are heavy duty, just like the crushers in the Philippines, can crush a ROM ore. Under Primary crushers are the Jaw Crushers and Gyratory Crushers.
Jaw Crushers: This equipment utilizes compression force when reducing the size of materials. Its processing speeds range up to 100-350 rev/min.
The materials used for the components of this crusher are made from cast steel replaceable liners made of Iron or Manganese Steel.
Jaw crushers are classed based on their receiving areas like the width of the plates and the gap between the jaws and opening.
Gyratory Crusher: This crusher has a long spindle and a conical grinding equipment made of steel. Normally, a Gyratory Crusher revolves between 85 and 150 rev/min in a conical path.
Its outer casing is constructed from heavy steel casting or plates. Then, these metals are fortified with reinforced alloyed white cast-iron.
Secondary Crushers can only manage to break down medium size rocks. There are five categories of crushers that fall under the description of a Secondary Crusher.
In terms of operation, a cone crusher is similar to a Gyratory Crusher. The distinction between the two is the lesser steep crushing chamber and more parallel crushing zones of a Cone Crusher, and the spindle in a Cone Crusher is supported, not suspended like the ones in a Gyratory Crusher.
The unique trait of a Roll Crusher is the use of compression in breaking down stone material.
Among all crushers, a roll crusher produces even size distribution.
Just like what the name states, Impact Crushers utilize impact for its process, compared to other crushers that use pressure.
Staying true to its name, a hammer mill crushes fragile stones against a rotating hammer. Before, the hammers used were made of Manganese Steel. It was later on changed to nodular cast Iron that contains Chromium Carbide, making the hammer strong against abrasions.
How Does a Crusher Work?
A stone crusher also has its own way of processing its products, just like any machine. Also, each type of crusher has their own unique style of crushing stones.
A container called a “Hopper” holds the uncrushed stones on top of the crusher. Stones are fed into the crusher either by gravity or a belt drive for a continuous and smooth transfer of the stones.
At the bottom of the equipment is a hole where the broken down rocks will exit. There are a few crushers that have holes leading to another crusher to ensure finer grains.
As the oldest modern prototype, Jaw Crushers have the simplest set up among all kinds of crushers. The physical appearance of a Jaw Crusher can be attributed to a giant V with metal walls. The walls are lugged by pulleys driven by a motor. Stones are crushed as the movable jaw goes towards the fixed jaw. As the angle between the two jaws decreases while the stones are slowly crushed, the pounded stones are discharged from the hole.
The process of an Impact Crusher is far different from that of a Jaw Crusher. A blow bar is installed inside and the rotor is driven to rotate at a high speed by a motor. As a large stones hit the blow bar, it will be launched to the impact devices installed inside the rotor. The rock materials will boomerang from the blow bar to the impact devices and back to the blow bar repeatedly. This operation pounds the rock materials into bits and small particles.
The shape and size of the products can be regulated by adjusting the clearance space between the impact devices and the rotor.
Cone Crushers and Gyratory Crushers
Cone Crushers and Gyratory Crushers have a similar process of breaking down rocks, but they only vary in design. The stone materials are inserted inside a compartment with a rotating grinder at the base. Crushing is done by squeezing the stone materials between the grinder and the container walls. As the stones fall further down into the grinder, it is pulverized into bits.
A Roll Crusher functions by placing a material between two rotating rolls and chiseling out the prescribed shaped using friction.
Initially, a Hammer Mill smashes the rocks towards a solid plate or a “beaker plate” that breaks the particles even more. Lastly, the particles are crushed by a discharge grate made of hammers. Afterwards, materials that have not been broken down into finer particles will again undergo the process of hammering.
What are the Different Applications of Crushers in the Various Industries?
It may not seem like it, but crushers can be used in various industries aside for construction.
Crushers are extremely useful in the Quarrying industry. After a rock is degraded to a manageable size using explosives, crushers can reduce the stone’s size even further for specific uses.
By using crushers, recycling companies can recycle inner waste instead of dumping them into the landfills.
Aggregates, specifically gravel, sand, and asphalt can be re-used.
This method not only protects the environment by lessening the waste, but also provide materials that could be used for future projects.
The initial materials broken down by crushers in the mining industry are Iron ore. Iron ores are strong and tough to process, which is why heavy duty crushers are used to get the job done.
Demolition jobs produce rubble and other scraps from the former structure, and instead of throwing those pieces at the landfills, they are broken down by crushers. These broken down rubbles are utilized again for future projects.
Depending on the rubble’s hardness, a Jaw, Cone, and Impact Crushers are usually used.
This industry specifically utilizes a rotary type of crushers due to its capability to mix and churn a large quantity of soft to medium-hard food products. By using a crusher, food products like vegetables, ice, candy, bones, pretzels, pasta, spices and chocolate blocks can be processed even at a volume of 3,500 cubic feet.
This versatile contraption has dated back to 2000 BC and started out as a simple “ball and socket” tool. Eventually, it was improved to being powered by a steam engine in 1806. Decades later, in 1840, a rotary type of prototype emerged.
The model that is still used today, the Blake Jaw Crusher, was designed in 1858 by Eli Whitney Blake. Another revolutionary crusher model was developed in 1881 by W. Gates, which is the Gates Gyratory Crusher. And in 1920, the first Cone Crusher was introduced.
There are two main kinds of Crushers: Primary and Secondary. The Primary Crushers are superior in terms of processing strength compared to a Secondary Crusher.
Under Primary Crushers, there are more specific types: Jaw Crushers and Gyratory Crushers. Jaw Crushers use compression force in breaking down stones. On the other hand, Gyratory Crushers breaks down materials by grinding, this process is also utilized by a Cone Crusher just with a few modifications.
Secondary Crushers have 4 specific kinds of categories under it. The first type is the Cone Crusher that resembles the breakdown process of a Gyratory Crusher. The second type which is the Roller Crusher utilizes the friction to generate even sized products. The Impact Crusher, which is the third type of Secondary Crusher, utilizes impact force in order to reduce the size of the materials. A Hammer Mill is the last type of Secondary Crushers, and staying true to its name, it utilizes a hammer that rotates to degenerate stones.
The crushers in the Philippines are an equipment that is versatile and can be utilized in different industries such as quarrying, recycling, mining, demolition, and even food processing. It is used in quarrying and mining when a further reduction is needed for the stone materials that was blown up. Excess sand, gravel, and asphalt are not wasted by re-processing (or recycling) with a crusher for future projects. Demolition projects can result to tons of rubble, which can still be re-used after being processed in a crusher. The most unusual and surprising industry to utilize a crusher is the food processing industry. By using a crusher, heavy volumes of materials such as ice, candies, and even bones can be processed.
Despite being only known by a few people; this machine is truly a must-have for any organization that needs to smash materials to a finer state. Even private individuals with a passion for tinkering or building find a use for this versatile contraption.
If you need a crusher here in the Philippines, look no further!
Our team here at Multico is more than willing to help.
Here at Multico, we promise to deliver impeccable customer service and the best crushers in the Philippines.
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