Electric Rock Crushers Explained: Features, Benefits, and Uses

Rock crusher machines and their aggregate products are very versatile and thus invaluable in many industries. Traditionally, diesel fuels powered these machines. But with the move to more environmentally friendly and sustainable options, electric crushers are now just as popular.

What are the features, benefits, and uses of such equipment? And what are the advantages of using an electric vs diesel-powered crusher? Read on to have electric rock crushers explained and these important questions about them answered.

What Is An Electric Rock Crusher?

Rock crushing equipment reduces rocks to finer particles like smaller rocks or aggregates like gravel and sand. Diesel fuel powers most rock crushers at mining quarries, as this eliminates the need for an on-site power source. However, many companies now use hybrid diesel-electric or fully electric crushers. An electric rock crusher does not need a diesel engine. Electricity from the grid powers the motor and all auxiliary drives. A generator allows more portability if necessary. Regardless of the energy source, a rock crusher breaks down rock material through impact, attrition, shearing, or compression. There are different crushing stages and types of rock crushers to handle these tasks.

Rock Crushing Stages & Types Of Rock Crushers

Depending on the rock size you require, there are three rock-crushing stages. 

Primary Crushing

Regardless of the final product you wish to produce, primary crushing is the first stage. Primary impact crushers break down very large rocks through impact with a large, solid object. You can also use a gyratory crusher. This has a conical-shaped head gyrating inside a bowl-shaped external shell.

Secondary Crushing

The next stage incorporates pressure and force to break the rock material down further, into even smaller pieces. This is the secondary crushing stage. The average input size ranges from 13″ to 4″.

A cone crusher presses the rock material against a rotating mantle to crush very hard rock. A roller crusher, which compresses the rock material between two parallel, turning cylinders, is a popular choice for softer, less abrasive materials.

Tertiary Crushing

The final stage is tertiary crushing. It reduces rock material further for mineral processing. Tertiary crushing passes the rock material through an impactor or cone crusher designed for smaller rocks. Screens filter out material too large for processing.

Uses Of Electric Rock Crushers

Rock crushers break down large amounts of rock material for easier ore processing and mineral extraction in the mining industry. They also produce aggregates, like gravel and finer sand-like products. These products, once mixed with binding mediums, make concrete products for the construction industry.

The aggregate industry also provides various materials for yard paving and landscaping businesses.

Benefits Of Electric Rock Crushers

Although you’ll get the job done with diesel-powered rock crushers, you’ll enjoy several benefits when you switch to using electric rock crushers.

An Eco-Friendly Option

Electric rock crushers are more eco-friendly than diesel-powered crushers. The main reason is that you don’t have to worry about the potential hazards of hydraulic pumps or diesel engines.

A fully electric rock crusher will not spill oils or fuel on the ground, even during mechanical failure. Electric motors are typically quieter than diesel engines in operation, too, and are energy-efficient and easier to maintain.

More Torque Makes Them Highly Efficient

Crushing and screening rocks require motors with high torque. Electric motors are perfectly suited to this. They convert over 90% of their produced energy into mechanical energy.  Diesel engines, on the other hand, lose heat and energy in the process.

Therefore, when you switch to an electric rock crusher, you enjoy higher efficiency and productivity.

Less Maintenance And Repairs

It’s often easier to maintain electric motors than fuel-operated ones. That means you’ll have less maintenance and fewer breakdowns to worry about. Electric crushers also typically last longer and have fewer issues than hydraulic motors driven by diesel engines.

Time lost on breakdowns and repairs is money lost. But with electric rock crushers, you’ll have less downtime, complete your orders on time, and operate at greater efficiency. This makes an electric rock crusher a sound business investment.

Meets the Growing Demand For Sustainability

There is a growing demand for better environmental practices and sustainability in the manufacturing and industrial sectors. This is why so many companies look at alternatives to fossil fuels to power their equipment.

Electric rock crushers are the solution in regions with heavier restrictions on fossil fuel emissions, and stricter sustainability requirements. They reduce reliance on non-renewable sources of energy and satisfy environmental regulations.

Conclusion

Electric rock crushers are more efficient, more sustainable, and better for the environment than traditional diesel-powered rock crushers. If you want to increase your uptime and reduce your maintenance and downtime, an electric rock crusher is the way to go.

Automation Electric & Control is well acquainted with the needs of the aggregate industry. We handle projects from crusher control and switchgear trailers to mobile operator cabs and more.  Contact us to learn what we can offer your business.