Hammer Crusher

Shanghe Hammer Crusher

A hammer crusher, or hammer mill, reduces material size through direct impact. Inside its chamber, a high-speed rotor fitted with swinging hammers repeatedly strikes fed material, shattering it against breaker plates until the fragments are small enough to pass through a screen at the bottom. This efficient impact crushing method makes it ideal for processing soft to medium-hard, non-abrasive materials across a wide range of industries.

Hammer crushers are valued for their versatility, high reduction ratio, and operational efficiency, making them a preferred solution across multiple sectors. Their core function of impact-based size reduction is applied to a broad spectrum of materials.

• Mining & Metallurgy: Crushing coal, limestone, gypsum, various ores (like bauxite), and industrial by-products such as slag and coke.
• Construction & Building Materials: Processing aggregates from concrete and brick, as well as raw materials like shale and clay for cement production.
• Energy Production: Sizing coal for power generation and preparing biomass (wood chips, agricultural waste) for biofuel and pellet production.
• Recycling Operations: Shredding and reducing materials like plastics, paper, and glass to facilitate reuse.
• Agriculture & Food Processing: Grinding grains, legumes, and spices for animal feed manufacturing and other food industry applications.

Advantages

The PCZ Hammer Crusher is engineered to optimize your crushing process with tangible benefits:

• Maximized Cost Efficiency: Our one-stage crushing process delivers a final, uniform product, potentially lowering your operational costs by up to 40% by eliminating secondary crushing stages.
• Unmatched Versatility: It is a proven solution across mining, cement, and construction for reducing medium-hard materials (<200MPa).
• Superior Productivity: Experience high-tonnage output—reaching up to 1200 t/h—without sacrificing energy efficiency.
• Cleaner & More Flexible Operation: The wet crushing capability (up to 15% moisture) allows for processing damp materials while controlling dust.
• Long-Term Reliability: We use premium, wear-resistant materials like high-manganese steel in critical components to maximize uptime and equipment longevity.

Types

1. By Rotor Configuration

• Single-Rotor Hammer Crusher: Employs one central rotor shaft. This simpler, more compact design offers a cost-effective solution for standard crushing tasks.
• Double-Rotor Hammer Crusher: Utilizes two parallel, counter-rotating shafts. This configuration provides a higher crushing ratio, increased throughput, and is particularly effective for processing sticky materials or achieving very fine output.

2. By Rotation Direction

• Reversible Hammer Crusher: Features a rotor capable of operating in both directions. This allows both leading edges of the hammers to be utilized, effectively doubling the service life of wear parts and reducing maintenance frequency.
• Irreversible Hammer Crusher: The rotor spins in one fixed direction. This straightforward, robust design is typically applied for crushing less abrasive materials.

3. By Hammer Mounting Method

• Swinging (Articulated) Hammer: Hammers are suspended on hinge pins, allowing them to swing back upon impact. This design offers protection against uncrushable objects and is well-suited for mixed or impure feed materials.
• Fixed (Rigid) Hammer: Hammers are permanently bolted or welded to the rotor. This arrangement provides a more direct transfer of energy, making it efficient for fine crushing of softer, more brittle materials like coal or gypsum.

4. By Capacity and Scale

• Heavy-Duty Hammer Crusher (e.g., PCZ Series): Engineered for high-capacity primary crushing in quarrying, mining, and cement production, with modern models capable of processing over 3000 t/h.
• Small Hammer Crusher (e.g., PC Series): Designed for low-capacity applications, laboratory work, or specialized production like brick manufacturing, with capacities typically below 100 t/h.

5. Specialized Industrial Types

• Ring Hammer Crusher: Specialized for the coal and coke industry, using ring-shaped hammers on a rotor for efficient impact crushing.
• Mobile Hammer Crusher: A self-contained, track- or wheel-mounted unit used for on-site processing in recycling, demolition, and aggregate production.
• Non-Clog Hammer Crusher: Incorporates design features such as a large crushing chamber, grates, or moving breaker plates to prevent material buildup when processing wet, sticky, or fibrous feed.

Working Principle

The crushing cycle follows a continuous sequence:

1. Feeding: Material is gravity-fed into the crushing chamber through a top-mounted feed hopper.
2. Primary Impact: A motor-driven rotor spins at high speed (typically 1,000–3,000 RPM), swinging a series of hardened hammers. These hammers deliver the initial, powerful blows that fracture the incoming material.
3. Secondary Fragmentation: The shattered particles are propelled against stationary breaker plates lining the chamber walls, causing further disintegration. Additional size reduction occurs through particle-on-particle attrition and grinding between the hammers and a bottom grate.
4. Sizing & Discharge: The final product size is controlled by a grate bar sieve at the chamber’s base. Only particles smaller than the grate openings are discharged; oversized fragments are retained for further crushing until they pass through.

Key Components & Functions

• Rotor: The central rotating assembly that transmits power and rotational kinetic energy to the hammers.
• Hammers: The primary impact elements mounted on the rotor. They are often designed as swinging (articulated) to withstand uncrushable objects, or fixed for maximum impact on specific materials.
• Grate Bars: A screen-like assembly at the discharge point that determines the maximum product size.
• Breaker Plates: Wear-resistant liners attached to the crusher housing. They protect the structure and provide a critical surface for secondary impact crushing.

Specification