Which crusher is most suitable for iron ore?

The selection of iron ore crushing equipment needs to be combined with the ore hardness, processing stage and finished product particle size requirements. The following is the analysis of the optimal solution in different scenarios.：

1. Coarse crushing stage: jaw crusher is the core equipment

Jaw crusher is the preferred equipment for processing large pieces of iron ore. Its deep cavity design can efficiently crush raw ore from 70-80 cm to medium-sized ore from 20-30 cm.The equipment has the characteristics of large crushing ratio and low energy consumption, and the structure is simple and easy to maintain. The hourly output of a single machine can reach more than 50-1000 tons, which is especially suitable as the “first line of defense” in the coarse crushing link.

2. Medium crushing stage: Cone crusher has significant advantages

For iron ore above medium hardness, the cone crusher can further crush ore below 30 cm to below 5 cm by relying on the principle of laminated crushing and a multi-cylinder hydraulic system.Its intelligent control system can monitor the operating status of the equipment in real time, and reduce the energy consumption of subsequent grinding through the “more crushing and less grinding” process, with a hourly output of up to 700-800 tons.The equipment performs well in terms of wear resistance and particle uniformity of finished products, and is suitable for large and medium-sized production lines.

3. Fine crushing stage: complementary application of impact crusher and roller crusher

Impact crusher: Suitable for scenes where ore below 5 cm needs to be finely crushed to 5mm. Efficient crushing is achieved through the impact principle of “stone to stone”. The hourly production range is 50-600 tons, which is common in processing processes that require direct sand making.

Hydraulic roller crusher: Fully hydraulic models such as Type 1212 perform well in ultra-fine crushing below 3mm. Double-roller extrusion crushing can accurately control the particle size distribution, and the degree of automation is high, which can reduce the phenomenon of over-crushing by more than 30%.Its compact structure is particularly suitable for retrofit projects with limited space, and the energy consumption when processing ore below 5 cm is 20% lower than that of traditional equipment.

4. Optimization of special scenarios: technological breakthroughs in fully hydraulic roller crushers

The latest hydraulic roller crusher (such as Type 2355) adopts a CNC pressure adjustment system, which can automatically match the crushing parameters for ores of different hardness, and realize the particle size accuracy control of ±0.5mm.The surface of its rollers is made of tungsten carbide composite materials, and the service life is more than 3 times higher than that of ordinary alloys. It has gradually become the mainstream choice in the field of ultrafine crushing of iron ore and tailings treatment.

Conclusion: Iron ore crushing needs to build a stepped process chain, and the combination scheme of “jaw crushing coarse crushing + cone crushing medium crushing + roller crushing fine crushing” is recommended.Among them, the hydraulic roller crusher has the advantages of low energy consumption and controllable particle size, which is more competitive in small and medium-sized projects and refined processing scenarios.Equipment selection should comprehensively consider ore characteristics, production capacity requirements and late maintenance costs, and maximize resource utilization through multi-stage crushing.