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Size Reduction Applications

 

Industries and applications

The following list provides just a few of the industries whose problems have been solved by Pennsylvania Crusher Corporation. Applications listed are just a few of the many that PCC machines have been successfully used to accomplish. There are THOUSANDS MORE! The input and output sizes stated in these typical applications are not intended to be limiting; other input and output sizes are possible. For advice on how to solve your crushing problems, contact us.

Abrasives industry

Reduce and/or reject used abrasive wheels for recycle. A Jaw Crusher or Reversible Impactor are good choices. 

Aluminum industry

  • Reduce Pitch Coke to a size suitable for the manufacture of anodes. A Hammermill is typically used.
  • Reduce petroleum coke to 4-6 mesh (3-4 mm) and finer for the manufacture of anodes and pot linings. A Hammermill is typically used.
  • Reduce used pot linings to reclaim trapped aluminum and cryolite. An Impactor, Jaw Crusher or Hammermill can be used in this application.
  • Reduce used pot linings and free trapped aluminum and cryolite. A Bradford Breaker can separate these materials.
  • Reduce Aluminum dross, free captured aluminum metal, and reclaim salt for furnace toppings. A Jaw Crusher or Impactor can be used.
  • Reduce Salt Cake from a rotary furnace to reclaim aluminum metal and rock salt. A Jaw Crusher or Impactor can be used, depending on the application details.
  • Reduce Aluminum Dross to free captured aluminum for recharging into melting furnace. A Reversible Hammermill is typically used.
  • Reduce "run of mine" Bauxite to a 3"-4" (75-100 mm) product for a primary reduction plant. A Non-Clog Hammermill is typically used.
  • Reduce baked and/or green carbon butts to 5" (125 mm) for suitable input for a secondary crusher while freeing the metal end plates. A DFC Hammermill is typically used.
  • Reduce 6" (150 mm) green or baked carbon butt material to various fine mesh sizes for manufacture of new carbon electrodes and pot linings. A Reversible Hammermill is typically used.
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Brick & tile industry

  • Reduce fired brick and/or tile to a size suitable for "grog" which is recycled into a "pug" mill with raw materials. This may require crusher output to be closed circuited with screen. An Impactor is typically used.
  • Reduce run of pit shale to 2" (50 mm) for feed to dry pans, rim discharge grinders or secondary Impactors and Hammermills. A Single Roll Crusher or Twin Rotor Impactor is used in this application.
  • Reduce shale to a minus 6-8 mesh (2-3 mm) product in closed circuit with screen. A Reversible Impactor, Hammermill or Twin Rotor Impactor are used in this application.
  • Reduce dry pan or rim discharge grinder tailings from screen to reduce circulating load on grinders. A Reversible Impactor is typically used.
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Cement industry

  • Reduce oyster and clamshells to 1" (25 mm) or finer product for cement kiln. An Impactor or Hammermill can be used depending on application details.
  • Reduce limestone or cement rock from 10" (250 mm) to 1" (25 mm) or finer in closed circuit for raw mill feed. A Reversible Impactor or Hammermill can be used.
  • Reduce run of quarry limestone, cement rock or shale to a 6" (150 mm) output size suitable for input to a secondary crusher. A Sizer, Single Roll Crusher, One-way Hammermill, or Jaw Crusher can be used, depending on application details.
  • Reduce run of quarry wet, sticky, plastic clay, shale or coral rock to a 2" (50 mm) product suitable for raw mill feed. A Sizer is typically used.
  • Reduce 4" (100 mm) gypsum rock to 3/4" (19 mm) output size for raw mill feed. A Granulator is most often used.
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Chemical industry

  • Crush fullers earth to 1/2" (12 mm) and finer product. A Twin Rotor Impactor or Reversible Impactor is often specified.
  • Reduce 8" (200 mm) diatomaceous earth to a 1" (25 mm) or finer output size. A Twin Rotor or Reversible Impactor can be used.
  • Reduce Sodium Silicate from a 4" (100 mm) input size to (6 mm) for processing. A Reversible Impactor is typically used.
  • Reduce run of mine Talc to 4"-5" for secondary reduction. A Sizer, Single Roll Crusher or Jaw Crusher is typically used.
  • Reduce 6" (150 mm) talc to 1" (25 mm) or finer product sizes for pulverizer feed. An Impactor is typically used.
  • Reduce run of mine Trona Ore (Soda Ash) to 6" (150 mm) suitable for secondary reduction. A Sizer or Single Roll Crusher is typically used.
  • Reduce 6" (150 mm) Trona (Soda Ash) to 3/8" (9 mm) or finer in closed circuit with a screen. A Reversible Impactor is typically used.
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Crushed stone industry

  • Reduce 4" (100 mm) limestone for Agricultural Limestone. A Reversible Hammermill or Cage Mill is typically used.
  • Reduce high calcium limestone to a fine product for "mine dust". A Reversible Hammermill or Cage Mill is typically used.
  • Reduce run of quarry Trap Rock to 4" (100 mm). A Jaw Crusher is typically used.
  • Primary crusher to reduce run of quarry limestone to 8" (200 mm) for secondary crusher feed. A Sizer, Single Roll Crusher or Jaw Crusher is typically used.
  • Reduce 8" (200 mm) limestone to minus 1" or finer in closed circuit with a suitable screen to remove desired product sizes. A Reversible Impactor is typically used.
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Fertilizer industry

  • Reduce Potash Compactor flake while producing minimum fines in closed circuit with a suitable screen. A Reversible Impactor is typically used.
  • Reduce Phosphate rock or pebble to a 1" (25 mm) or finer product for making Diamonium Phosphate. A Reversible Impactor is typically used.
  • Reduce agglomerated lumps of super phosphate. A Reversible Impactor is typically used.
  • Crush lumps of Dicalcium Phosphate to 3" (75 mm). A Sizer or Single Roll Crusher is typically used.
  • Reduce lumps of Diamonium Phosphate and other granular fertilizers to 1/2" (12 mm) or finer products. A Reversible Impactor is typically used.
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Foundry industry

  • Crush lumps of used foundry sand to grain size for reuse. An Impactor is typically used.
  • Reduce graphite, graphite electrodes, graphite crucible scrap and graphite ore to a minus 1" (25 mm) or finer product. An Impactor is typically used.
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Glass industry

  • Crush glass bottles, plate glass or lump glass (Cullet) to minus 1" (25 mm) for furnace charging. A Jaw Crusher is typically used.
  • Crush glass frit for glass linings in metal tanks and water heaters. An Impactor is typically used.
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Gypsum industry

  • Reduce run of mine Gypsum Rock to a 5" (125 mm) product for shipment from the mines to wallboard plants. A Sizer or Single Roll Crusher is typically used.
  • Reduce 3" (75 mm) Gypsum to a 1" (25 mm) or finer product for pulverizer feed in wallboard plant. A Hammermill or Granulator is typically used.
  • Reduce 6" (150 mm) Gypsum rock received at wallboard plant to 2" (50 mm) suitable for feed to Hammermill or Granulator. A Sizer or Single Roll Crusher is typically used.
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Lime industry

  • Reduce 4" pebble, quick and other burnt lime to a 1/2" (12 mm) or finer product size as required. A Double Roll Crusher is suitable for this application, or a hammermill for output sizes smaller than 1/4" (6 mm).
  • Reduce various forms of burnt lime to various product sizes required by the industry. A Granulator or Hammermill is used for this application.
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Mining - Anthracite coal

  • Reduce coal from the cleaning plant to the product sizes required. In the United States these are called pea, nut etc. Also can produce filter size coal. A Granulator is typically used.
  • Reduce run of mine Coal to 4" (100 mm) while removing rock and debris. A Bradford Breaker is used to separate while crushing.
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Mining - Bituminous coal

  • Reduce mine rock from cleaning plant and Bradford Breaker to a suitable size for handling or conveying to a waste dump. A Sizer, Single Roll Crusher or Jaw Crusher is typically used.
  • Reduce clean coal to 2" (50 mm) suitable for power plants. A Granulator or Sizer is typically used.
  • Reduce 3"coal middlings and separate the coal from the rock for recycle into cleaning plant. A Granulator is typically used.
  • Reduce deep-mined or strip-mined run of mine coal containing rock and other debris to 4" (100 mm) size suitable for prep plant feed while screening out the large rock and uncrushables. A Bradford Breaker is typically used.
  • Reduce the 4" (100 mm) coal from a Bradford Breaker to a 2" (50 mm) product suitable for shipment to power plants. A Granulator is typically used.
  • Reduce run of mine coal to a 5" (125 mm) product suitable for preparation plant feed. A Sizer or Single Roll Crusher is typically used.
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Mining - Sub-bituminous coal & lignite

  • Primary crusher to reduce run of mine coal to a 6" (150 mm) product. A Sizer or Single Roll crusher is typically used.
  • Secondary Crusher to reduce the primary crushed 6" (150 mm) coal to a 2" (50 mm) product for shipment or conveying to power plants. A Granulator is typically used.
  • Reduce run of mine oil shale to a 5" (125 mm) product. A Sizer or Single Roll Crusher is generally used.
  • Reduce the 5" (125 mm) oil shale crushed in primary crusher to a 1" (25 mm) or other specified size, with limited unwanted fines, as required for retort feed. A Reversible Impactor is suitable.
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Petroleum industry

  • Reduce 4" (100 mm) petroleum coke to a 2" (50 mm) product for shipment to power and industrial plants as boiler fuel. A Coalpactor or FBR Hammermill would be used for this application.
  • Reduce wet petroleum coke cut from the coking drum to 5" (125 mm) output size suitable for feed to a secondary crusher or for shipment. A Sizer or Single Roll crusher is typically used.
  • Reduce the run of pit tar sand to 5" (125 mm). A Sizer or Single Roll Crusher can be used.
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Power industry

  • Reduce 3" (75 mm) coal as received at plant to a 1-1/4" (30 mm) product suitable for pulverizer feed. A Granulator is used.
  • Crush 3" (75 mm) Bituminous or Sub-bituminous coals to a 4 mesh (5 mm) output size suitable for Cyclone Furnace Firing. A Reversible Hammermill is used.
  • Reduce wet bottom boiler clinker to a minus 1" (25 mm) product for pumping to ash pond. Can replace most Allen Sherman Hoff or United Conveyor Clinker Grinders and has superior features. A Clinker Crusher is used.
  • Reduce 4" (100 mm) petroleum coke to a minus 4 mesh (5 mm) product for Cyclone Furnace firing. A Reversible Hammermill is typically used.
  • Reduce 4" (100 mm) Petroleum Coke to a minus 1-1/4" (30 mm) product for pulverizer feed. A Granulator is typically used.
  • Reduce limestone to 1" (25 mm) to 3/8" (10 mm) for suitable feed size to ball mills making scrubber size material. An Impactor is typically used.
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Power industry - Fluid bed boilers

  • Size lignite, bituminous coal, anthracite or sub-bituminous coal to 3/4" (19 mm) or less for fluid bed boiler. A Granulator is typically used.
  • Reduce lignite, sub-bituminous or bituminous coal to a size suitable for use in a fluid bed boiler.  A Coalpactor or Reversible Hammermill can be used.
  • Reduce limestone to a size required by the boiler as sorbent. An Impactor, a Hammermill or a BMR Grinding Mill can be used.
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Power industry - Waste fuels - Fluid bed boiler

  • Reduce bituminous gob (refuse) or anthracite culm (refuse) to a suitable size product meeting the boiler manufacturer's specifications. An FBR Reversible Hammermill is typically used.
  • Reduce 2" (50 mm) limestone to a size suitable for use as a sorbent in the fluid bed.  A BMR (Rod Mill) or Hammermill is typically used.
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Steel industry

  • Reduce coking coals to an 85% minus 1/8" (3 mm) product for charging in coke ovens. A Coalpactor is typically used.
  • Reduce 12" (300 mm) Open Hearth Blast Furnace slag for road aggregate while freeing trapped metal for reclamation. A Jaw Crusher or Special CF Reversible Impactor is typically used.
  • Crush slag for road aggregate to 2" (50 mm) and larger. A Jaw Crusher is typically used.
  • Crush various ferroalloys for adding to the furnace. A Jaw Crusher is typically used.
  • Crush iron ore for Sinter process or furnace sizing. A Jaw or Impactor can be used for this application.
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Metallurgical industry

  • Reduce pieces of Tungsten Carbide to 1" (25 mm) or finer product sizes used as furnace additives or for making welding rods. An Impactor is typically used.
  • Crush 8" (200 mm) high and low carbon ferro-chrome to a 4" (100 mm) product. A Special Primary Crusher is typically used.
  • Reduce 4" (100 mm) high and low carbon ferro chrome to a 1" - 2" (25-50 mm) product for feed to a cone crusher or as furnace additive. A Heavy Duty Secondary Jaw Crusher is typically used.
  • Crush various ferrous alloys (ferro vanadium, ferro nickel, ferro silicon, ferro molybdenum) to 1" - 2" (25 - 50 mm) for furnace additives. A Jaw Crusher is typically used.
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Sand & gravel industry

  • Reduce run of pit gravel to 3" (75 mm) for secondary crusher feed material. A Jaw Crusher is typically used.
  • Break rounded river gravel to create broken surfaces to meet concrete aggregate specifications. A Reversible Impactor is typically used.
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Refractories industries

  • Reduce synthetic mullite or natural mullite to minus 1" (25 mm) or finer for making refractory bricks. An Impactor is typically used.
  • Crush magnesite brick to a size suitable for reuse in the clay mix. A Reversible Impactor is typically used.
  • Reduce Flint Clay to a product suitable for "Pug mill" feed. A Twin Rotor Impactor is typically used.
  • Reduce used or imperfect fired or unfired brickbats to minus 1" (25 mm) or finer in one pass or in closed circuit with a screen. A Jaw, Impactor or One-Way Hammermill can be used.
  • Crush dry pan or rim discharge grinder tailing to 6-8 mesh (2-3 mm) in closed circuit with a screen to relieve circulating load of grinders. A Reversible Impactor is typically used.
  • Crush fired refractory in closed circuit for introduction into a "pug" mill with raw material. Crushed material is called "grog." A Reversible Impactor is typically used.
  • Crush waste brick to suitable size for road aggregate or for landfill. A Jaw Crusher and Reversible Impactor are typically used.
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