Jaw crusher VS impact crusher | How to choose right rock crusher

Jaw crusher and impact crusher are two very important crushing equipment in the stone crushing plant. The obvious difference between jaw crusher and impact crusher is structure and working principle. Jaw crusher uses compressive force to break hard stone. The material is squeezed and crushed in the crushing chamber composed of movable jaw and fixed jaw. Impact crusher adopts the principle of impact crushing, the material is repeatedly impacted and crushed between the rotor (blow bar) and the impact plate. Now we focus on the analysis of their differences in actual production from 6 key points.

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1. The scope of application is different

The jaw crusher can crush all kinds of soft and hard materials, and the compressive strength is between 300-350Mpa.
Impact crusher is suitable for crushing materials with low toughness and brittle materials with medium hardness and below, such as limestone, clay, calcium carbonate, gypsum etc. If it is hard, it will cause great damage to the wearing parts and shorten the service life.

2. Material particle size

In the stone crushing plant, jaw crushers are commonly used as primary crushing to crush large pieces of material, and it can allow ore below mm to feed (depending on the equipment model and manufacturer). And impact crushers are commonly used for secondary or tertiary crushing equipment for medium or fine crushing. The allowable feed size range is not as wide as that of jaw crushers.

3. Different production capacity

In general, the capacity of jaw crusher is greater than that of impact crusher. Jaw crusher can reach 600-800t (depending on the manufacturer and product model), and the hourly output of impact crusher is about 260-450t.

4.Different output particle type

As a coarse crusher, the jaw crusher has a relatively large discharge fineness, generally below 300-350mm (depending on the manufacturer and product model), and the impact crusher is a medium or fine crusher, and its discharge fineness is of course smaller.

The particle shape of the material after extrusion treatment by jaw crusher is not ideal, and the content of needles is high. Impact crusher is a product with good particle shape and less edges and corners in the crushing equipment. It has a finer discharging particle size and its particle shape is also better than that of cone crusher.

Therefore, in actual production, the jaw crusher is usually equipped with an impact crusher for further shaping, and the two are also a common combination in the crushing production line.

5. Different prices  

Which is better, jaw crusher or impact crusher? According to the market sales situation, the overall sales of jaw crushers are more than impact crusher, mainly due to its versatility and flexibility. It can not only be used as a crushing equipment alone, but also can combine with other machines in various production lines. It is a cost-effective one among all crushing equipment.

The price of a jaw crusher generally ranges from tens of thousands to hundreds of thousands (Chinese RMB). The specific price can be consulted by the manufacturer.

The jaw crusher mentioned in this article is mainly coarse jaw crusher. For fine jaw crusher, it is mainly used as intermediate crushing equipment together with cone crusher, impact crusher, hammer crusher, etc. Therefore, there will also be a jaw crusher followed by a jaw crusher ( PEX fine jaw crusher) configuration. To sum up, when choosing crushing equipment, users should configure it reasonably according to production requirements in order to obtain ideal production capacity and benefits.

People Frequently Asked Questions-FAQ:

1.What are the disadvantages of impact crushers?

Impact crushers typically require more maintenance than compression style crushers – especially if crushing hard and abrasive materials. This is because the material in an impact crusher is constantly colliding within the crusher at high velocities to break the rock apart.

2.What crusher is best for concrete?

In our professional opinion, an impact crusher is the best choice for most concrete, or asphalt recycling applications. It mainly uses impact force to break stone into smaller size. Although jaw crushers do a dependable job. Jaw crusher capacities vary depending on the make and the model being used. Another disadvantage of jaw crushers is that the resulting particle sizes can sometimes be a little uneven.

3.What is a impact crusher used for?

The impact crusher is commonly used for the crushing of limestone, coal, calcium carbide, quartz, dolomite, iron pyrites, gypsum, and chemical raw materials of medium hardness.

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The NGS Impactor represents the next generation secondary Impact Crusher. Still unmatched in the industry, the NGS Impactor is engineered to bring more profitability to aggregate and mineral processing operations. Developed to mimic the productivity of its predecessor, the Impact II, this impactor generates a better, highly cubical product while reducing operating expenses. 

The NGS Impactor reduces downtime for adjustments, requires fewer wear parts to inventory and can be modified in the field to accommodate changes in the application and product requirements. The NGS Impactor is available in seven different model sizes, and each is uniquely designed with a means to retrofit most any Andreas-style Impactor at minimal cost. Optional features are available to enhance the simplified curtain adjustment to involve adjust-on-the-fly or advanced touchscreen automation capability. Combining 35 years of field experience with the latest technology available, McLanahan continues to expand the features of the NGS Impactor. 

Why McLanahan NGS Impact Crushers

McLanahan Corporation has a long and prosperous history in the mineral processing industries. We offer crushing solutions for soft materials like coal and hard and abrasive materials like granite or basalt.  Not only does McLanahan understand the process, but we are keenly aware of the issues that affect your bottom line. When considering an Impact Crusher, you can rely on McLanahan to analyze your application and recommend the most appropriate avenue.

The NGS Impact Crusher commonly takes primary-run limestone from either a Jaw Crusher or impact breaker and reduces it into a construction grade aggregate. The optional third curtain assembly makes it possible to increase the amount of chip stone for asphalt and some concrete mixes. The adjustability in the curtains, at various rotor speeds, generates output gradations that can be manipulated in many ways. The NGS Impactor is equipped with wear resistant liners and hammers cast from various chromium alloys. Even applications in tough river gravel and abrasive concrete rubble tend to be profitable with the NGS Impactor. The rotor speed and the right hammer alloy opens a wide opportunity for material reduction in industries where new markets are growing. If your operation could benefit from higher reduction ratios while generating a cubical product with superior soundness, consider the NGS Impact Crusher. 

McLanahan offers the largest selection of Impact Crushers in the country. We have Impactors that have been in operation for more than 50 years and have earned a reputation of providing reliable equipment with unmatched service and support in the mining and aggregates industries. Choosing an NGS Impactor for your operation enables us to prove, once again, our dedication to the industry and to your success.

How NGS Impact Crushers Work

The NGS Impact Crusher is an Andreas-style impactor with basic features like disc rotors, reversible hammers, common wear liners, and hydraulic hood for access. However, the NGS advantage begins with the material flowing down a feed chute at an optimal angle. The feed chute allows the material to enter the rotor circle at a precise point where the hammers have the greatest affect in shattering the rock. The geometry of the primary curtain contains the initial spray of shattered rock and diverts the rock back into the hammer circle. The secondary curtain then receives a similar spray of finer particles as the material works its way around the rotor, coming into contact repeatedly with the hammers. 

A dual curtain impactor typically provides a 10:1 reduction in a limestone material. The NGS Impact Crusher offers the option of a third curtain, which in some applications may provide more than a 20:1 reduction. As with all Universal impactors, the NGS Impact Crusher provides a greater level of control over the flow of the material through the reduction process. The hammer profile in the NGS is an S-shape, which provides a protruding leading edge. As the hammer wears down, it continues to strike the stone with a sharp edge. This keeps the material flow more centered on the curtains. As the hammers wear, the gap between the hammer tip and the curtains becomes greater. Measuring from the bottom edge of the curtain, when the gap expands with every 1” of hammer wear, the resulting output gradation will become noticeably coarser.

The NGS Impact Crusher is extremely easy to adjust, no heavy wrenches or cheater bars needed. All it takes is a simple pull on the hydraulic lever. Then, lift the shims from the cradle, secure them in the shim pack with a thumb-screw, and let off the hydraulic cylinder. Check the gap through the inspection door, and you're done.

When the hammers are spent, the replacement process is quick and easy. A rotor lock and special lifting tool is included with every NGS Impactor as a safety-first initiative. Once the new hammers are in place, reset the curtain gaps, and the crusher is ready. 

With any Impact Crusher, it is always important to check for loose hardware. We are proud of the fact that our NGS line of crushers have the largest inspection and maintenance doors of any secondary impactor on the market. Access is critical. Providing more visibility empowers operators to be more proactive. McLanahan now offers the NGS Impactor with the ability to be adjusted while under full load. Watch the discharge conveyor, and allow the rock to grow or shrink with the touch of a finger.

Want even more control? We offer a complete automation program with touchscreen to adjust the gap settings either for hammer wear or ever-changing product demands. This full automation feature also includes hands-free calibration capability. Just give the command and let the crusher adjust accordingly. 

The NGS Impact Crusher generates a better, highly cubical product while reducing operating expenses.

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Features & Benefits

• Two independent gravity hung impact curtains, both suspended from the same pivot point, provide unmatched ability to hold gap settings against surges in material flow
• A third curtain, when needed, can be added to the Impactor as a field kit in the event future opportunities arise, and once installed, can be fully retracted to function as a deflector plate
• The impact curtains are equipped with interchangeable cast liners of chromium alloy, bolted into place and available in half sizes for easier handling
• Optional fabricated liners are available for most models and stretch the full width of the curtain, and they can be used in various positions throughout the Impactor
• The impact curtains are equipped, as standard, with hydraulic assisted shim adjustment, and are engineered to provide quick and simple replacement when necessary
• To access the interior of the crusher, the housing hydraulically opens with the hood retracting beyond the center of gravity, engaging a mechanical hood lock for added safety
• A rotor lock inserts into the rotor of a positive means to keep the rotor from turning during maintenance
• The rotor assembly can be a three-bar, four-bar, or even five bar design
• Hammers are held into the rotor with easy-to-remove-and-install L-blocks that reduce downtime and provide a positive means to retain the hammers during operation
• Large access doors on the top, back and sides of the Impactor provide unmatched access to the interior of the crusher for inspection and maintenance
• Rotor assembly features a rotor weldment, secured to the shaft with a keyless assembly and mounted on spherical roller bearings