Impact crusher

Exploring the Impact Crusher Market Dynamics

Market Overview: The global impact crusher market has shown robust growth, with the broader Crusher & Shredder Market expanding from USD 995.63 million in 2023 to USD 1.04 billion in 2024, and projected to reach USD 1.46 billion by 2030 at a CAGR of 5.63%, according to 360iResearch. This growth is primarily driven by increasing demand across various sectors, including construction, mining, and recycling. The U.S. market, valued at approximately $557 million in 2023, is witnessing significant investments in infrastructure and industrial activities, further propelling the demand for impact crushers. Additionally, China is anticipated to experience a remarkable growth rate of 9.3% CAGR, reaching $761.4 million by 2030, indicating a strong regional demand for these machines.

Industry Insights: The impact crusher market is influenced by several key factors, including technological advancements and shifts in consumer behavior towards more efficient and sustainable machinery. As industries increasingly focus on reducing operational costs and enhancing productivity, the preference for electric and automated impact crushers has surged. Furthermore, the ongoing trend of urbanization and infrastructure development has led to a rise in construction activities, which in turn fuels the demand for impact crushers. Major players in the market are adapting their strategies to cater to these changes, with an emphasis on innovation and eco-friendliness. The industry's growth trajectory suggests that the impact crusher market is well-positioned to capitalize on emerging opportunities, particularly in niche markets such as recycling and waste management.

Types of Impact Crushers

An impact crusher is an industrial machine used to crush stones and other hard materials. Different types of impact crushers are available to suit specific crushing needs in a production line.

• Horizontal Shaft Impact Crushers

  A horizontal shaft impact crusher (HSI) functions quite a lot like a hammer mill. It is built with a massive rotor that flings the material at a fixed plate. This impact forces the material to break into smaller sizes. HSI impactors are typically used for softer and less abrasive stones. They are very effective for crushing limestone and gypsum.

• Hydraulic Impact Crushers

  An impact crusher’s driving force is usually a fly wheel. However, some models use hydraulic energy to carry out the impact crushing. A hydraulic impact crusher (HPI) crushes hard materials using high-pressure liquid power. These crushers are more massive to accommodate the hydraulic components. They tend to have higher crushing ratios and offer more controlled sizes of end products.

• Vertical Shaft Impact Crushers

  These crushers are also known as VSI crushers. A vertical shaft impact crusher (VSI) has the motor on top, unlike the HSI. The motor drives the rotor directly, which then throws the stone upwards and against the surrounding anvil ring. The crushing forces may be gravitational pull or the surrounding anvil ring. The crushing force is usually more than that of horizontal crushers. The end products have fine aggregates and are excellent for use in asphalt and concrete mixtures.

• Reversible Impact Crushers

  This type of impactor can change the direction of the rotor after a certain period. This makes it easy to maintain and wear parts. It also evens out the abrasion on the parts used to crush the material. A reversible impact crusher is more efficient and can be used for a long time without incessant stoppages for maintenance.

Specification & maintenance of impact crushers

Some specifications of an impact crusher are as follows:

• Capacity: The capacity of an impact crusher is represented by the total production volume it can achieve in one hour, usually related to the rotor diameter and length, feed port size and other parameters. The typical capacity of small impact crushers is between 20-50 tons per hour, while that of large ones can reach up to hundreds of tons per hour.
• Power: The working power of the impact crusher is represented by the motor power. Different power affects the crushing ability and processing capacity. For example, the motor power of small impact crushers may be around 15-30 kilowatts, while that of large ones is 100 kilowatts or more.
• Crushing ratio: The crushing ratio is the ratio between the sizes of raw materials and crushed materials. It measures the size reduction capability of the impact crusher. For example, an impact crusher may have a crushing ratio of 10:1, meaning it can convert 10 cubic meters of raw materials into 1 cubic meter of crushed materials.
• Discharging size: The discharging size range is the size of the crushed materials. Different applications may require different particle sizes. For example, an impact crusher may offer the option of 5-20mm particle sizes for the aggregate industry and 0.5-3mm for the powder-making industry.
• Materials: The impact crusher's casing, rotors, hammers, and other components are all made of high-strength alloy steel to improve the machine's hardness and durability.

In addition to the specifications, the maintenance of impact breakers is also crucial.

First, regularly check the fasteners to see whether they are loose or damaged. Please tighten and replace them if necessary. Second, check the condition of the hammers and impact plates to see whether they are worn or damaged. Impact crushers have inherent advantages in terms of easy-to-replace parts and repair.

Third, ensure the lubrication of bearings and rotors to avoid excessive abrasion and heating. A detailed maintenance schedule can assist in the upkeep of the impact crusher:

• Daily: Check the bolts and anti-loose parts for lubrication of bearings and check the working conditions of impact plates and hammers.
• Weekly: Clean the inside and outside of the impact crusher. Check the belt and pulley to ensure proper slack and alignment, lubricating each bearing and gear case applying grease for bearings, seal rings, and o-rings.
• Monthly: Check the motor and electric parts. Check for wearing along with the adjusting parts and transmission parts. Check the impact crusher's foundation and support frame.
• Quarterly: Replace the bearing grease. Check the wear and tear of the transmission belt and adjust its tightness to inspect the impact plate and hammer for any signs of failure or excessive wear.

Usage scenarios of an impact crusher

An impact crusher is essential for construction projects. This machine helps to break large concrete pieces, stones, and rocks into smaller ones. The resulting smaller pieces are more manageable and convenient for further use or transportation. In building new roads or repairing old ones, an impact crusher can help crush the concrete used for the old road or demolish an old building.

Using an impact crusher is much more convenient and easier than using a manual or portable rock crusher. The material produced is uniform and more refined from an impact crusher than any portable rock crusher. The machine's production is more significant, and its use is more effortless. Full-sized boulders that might pose a problem to a construction site are easily broken by the impact crusher into smaller stones and gravel that can quickly be used for a project.

Quarries mainly use impact crushers. A primary impact crusher takes large volumes of feed. It serves as the first stage of crushing. The material produced after the first stage will usually go through a secondary impact crusher, which produces a more refined and precise end product.

Besides construction projects and quarries, an impact crusher can also be found in the recycling industry. The impact crusher makes it easier to recover valuable reusable materials found in construction waste, mining waste, or any other valuable waste material. The recycling industry capitalizes on these reusable materials to reduce costs.

How to choose impact crushers

Several factors need to be considered when selecting the appropriate impact stone crusher for a particular application or use. These factors are consistent with the popular demand for how to choose an impact crusher.

• Production requirement analysis: This involves studying and resolving the maximal acceptable feeding size, required production capacity, and desired final product characteristics, such as shape and gradation.
• Appropriate selection of impact crusher types: After analyzing the production requirements, it becomes easy to match and select the typical impact crusher. Remember that different impact crushers have features that make them suited for different applications. For example, an industrial vertical impact crusher might be suitable for producing sand and shaping materials, while a primary or secondary horizontal impact crusher might be better for reducing the size of large rocks.
• Evaluation of the crusher's specifications: Pay attention to the technical specs provided by the manufacturer or supplier. This includes the crusher's capacity (usually expressed in tons per hour), power requirement (kilowatts), maximum feeding size, and weight.
• Consideration of the machine's design and construction: It is essential to inspect the machine's design and construction. Consider the machine's material, wear part accessibility, and overall build quality. It helps to ensure proper feed distribution to avoid blockages and optimize crushing efficiency. Wear parts like blow bars and impact plates are easily accessible for quick replacement to reduce maintenance downtime.
• Examination of the automated features: Impact crushers with automated features make it possible to control and monitor the machine's operation in real time. These features enhance security, optimize performance, and simplify maintenance tasks. Consider these automated features and choose a model that has a sense of safety and performance.
• Environmental and logistical considerations: This includes the impact of the chosen machine on the environment (in terms of noise and air pollution) and the transportation and installation logistics.
• Maintenance & support services: Consider the availability of support service and maintenance for the chosen impact crusher. The support and maintenance help to ensure a smooth operation and minimize downtime for the business.

FAQ

Q1: What kind of motor do impact crushers have?

A1: Impact crushers are usually equipped with asynchronous AC motors with different power requirements, depending on the crusher's size and the material to be broken.

Q2: What kind of bearings do impact crushers use?

A2: The rotor bearings of impact crushers are mainly double-row spherical roller bearings. The double-row bearings can withstand radial loads and axial loads in both directions, allowing them to withstand the heavy weight of the crusher rotor. Meanwhile, they have greater stability and bearing capacity. For some small-sized crushers, single-row bearings can also be used.

Q3: How to maintain an impact crusher?

A3: Regular inspections should be performed to check whether the internal parts are wearing out, particularly the impact plates and blow bars. If any parts show signs of wear, they should be repaired or replaced promptly. Besides, lubricating the equipment parts can reduce friction and wear and improve the impact crusher's efficiency and service life.