Types of Crushers Used in Quarrying and Aggregate Production
A practical guide to jaw, cone, gyratory, impact, and VSI crushers: how each type works, where it fits in a crushing circuit, and the key parameters that drive performance.
Why crusher type selection matters
The type of crusher you select at each stage of a plant determines throughput capacity, product gradation, product shape, operating cost, and the maintenance profile of the machine. The wrong crusher type for an application leads to excessive wear, poor product quality, high operating cost, or all three.
Most crushing plants use different crusher types at different stages: a jaw crusher for primary reduction, a cone for secondary and tertiary, and sometimes an impact or VSI crusher for final shaping or fine aggregate production. Understanding what each type does, and where it fits, is the starting point for building a credible plant design.
In Quorr, each crusher type is modelled with its own performance characteristics. Selecting the right type in your plant simulation gives you a more accurate prediction of throughput and product quality than using a generic crusher model.
Crusher type selection at a glance
| Crusher type | Typical stage | Best for | Watch-outs |
|---|---|---|---|
| Jaw | Primary | Large, irregular feed; hard rock; robust operation | Not ideal for final product shape; coarser product PSD |
| Gyratory | Primary | Very high throughput; continuous feed; large operations | High capital cost; significant civil infrastructure required |
| Cone | Secondary / Tertiary | Hard, abrasive rock; tight product gradation; closed circuit | Sensitive to feed top size; needs controlled, even feed |
| HSI | Primary / Secondary | Softer rock; cubical product; high reduction ratio | Wear cost can become prohibitive in hard, abrasive rock |
| VSI | Tertiary / Quaternary | Shape improvement; manufactured sand; fine aggregate | Feed grading and wear rate are critical; not suited to coarse primary feed |
This table is a general guide. Crusher selection depends on the specific application, feed material, product requirement, throughput, and operating context. Always verify against manufacturer data and engineering judgement.
Jaw crushers
A jaw crusher uses a fixed jaw plate and a moving jaw plate in a reciprocating motion to break rock by compression. The feed material enters the top of the crushing chamber and is progressively reduced as it moves toward the narrower bottom, where it exits at the closed side setting (CSS).
Jaw crushers are the most common primary crusher in quarry and aggregate applications. They handle large, blocky feed from blasting well, are mechanically robust, and are relatively straightforward to operate and maintain.
Typical specifications and performance
- Feed opening: from approximately 400×600 mm (small) to 1500×1200 mm (large) — dimensions vary significantly by manufacturer
- Maximum feed size: depends on manufacturer definition and chamber geometry; many use a rule of thumb of 80–85% of the relevant opening dimension, but manufacturer data should take precedence
- CSS range: typically 50–200 mm depending on model size
- Throughput: from 50 t/h (small models) to 800+ t/h (large models at wide CSS) — actual values depend on feed material, CSS, rock strength, moisture, and liner condition
- Applications: primary crushing of granite, basalt, limestone, sandstone, and most hard rock types
All capacity ranges are illustrative. Actual capacity depends on manufacturer data, CSS, feed gradation, rock strength, moisture, bulk density, liner condition, and operating practice.
How jaw crushers are modelled in Quorr
In Quorr, a jaw crusher is placed at the primary stage of the flowsheet. You set the CSS and the simulation calculates throughput and discharge gradation based on the equipment's performance data. Changing CSS shifts the discharge gradation and throughput in the direction expected from the manufacturer's performance curves.
Gyratory crushers
A gyratory crusher uses a conical mantle that gyrates inside a concave bowl. The crushing action is continuous rather than reciprocating, which gives gyratory crushers a higher throughput capacity than jaw crushers of comparable size. They are used at the primary stage in large mining and quarry operations where throughput is the priority.
Typical specifications and performance
- Feed opening: from approximately 900 mm to over 1500 mm (top shell diameter) — varies significantly by model
- Throughput: typically 1500–6000+ t/h depending on model and CSS
- CSS range: typically 130–230 mm
- Applications: primary crushing in large quarries and open-pit mines where throughput exceeds what a jaw crusher can deliver
- Machine weight: 100–500+ tonnes, requiring significant civil infrastructure
When to specify a gyratory rather than a jaw
Gyratory crushers are typically specified when the primary crushing throughput requirement exceeds approximately 1000–1500 t/h, the feed is continuous (from a conveyor rather than batch dumping from haul trucks), or the operation is large enough to justify the higher capital cost and civil infrastructure requirement.
Cone crushers
A cone crusher uses a gyrating mantle inside a concave bowl to crush rock by compression. Unlike a gyratory crusher, the cone crusher is designed for secondary and tertiary reduction: it accepts a smaller feed size and produces a finer, more uniform product with a tighter particle size distribution.
Cone crushers are the workhorse of the secondary and tertiary crushing stages in most quarry and aggregate plants. They commonly run in closed circuit with a vibrating screen to produce a product within a defined size range, with oversize material returning to the crusher as recirculating load. This closed-circuit arrangement is the most common context in which recirculating load is discussed.
Typical specifications and performance
- CSS range: typically 6–50 mm (tertiary) to 20–75 mm (secondary) — varies by manufacturer and chamber
- Eccentric throw: typically 15–40 mm, affecting throughput and product shape
- Throughput: 100–1000+ t/h depending on model size and CSS
- Chamber types: extra coarse (EC), coarse (C), medium (M), fine (F), extra fine (EF), each for a different reduction range
- Applications: secondary and tertiary crushing of hard rock; capable of handling abrasive materials
How cone crushers are modelled in Quorr
In Quorr, a cone crusher is placed at the secondary or tertiary stage. You set the CSS, chamber type, and eccentric throw. The simulation calculates throughput and product gradation, and in a closed circuit configuration, calculates the recirculating load from screen oversize back to the cone inlet.
Impact crushers (HSI): horizontal shaft impactors
A horizontal shaft impactor (HSI) uses rotor-mounted blow bars spinning at high speed to strike incoming feed material. The impact breaks the rock, and further reduction occurs as material strikes the apron plates inside the chamber. HSI crushers produce a more cuboid product shape than compression crushers but generate more fines.
HSI crushers are used in primary and secondary applications for softer, less abrasive rock types such as limestone, chalk, and some sandstones. They can process harder materials in some applications, but they are generally less preferred for hard, abrasive rock because wear costs on blow bars and apron plates can become prohibitive.
Typical specifications and performance
- Feed size: up to 500–1200 mm (primary HSI) or 150–300 mm (secondary HSI) — varies by rotor diameter and configuration
- Throughput: 100–1500 t/h depending on rotor size and configuration
- Product gradation: finer and more cuboid than jaw or cone output for the same feed
- Wear rate: sensitive to rock abrasivity; well suited to limestone, gypsum, chalk, and recycled concrete
- Applications: primary crushing of soft to medium-hard rock, demolition recycling, cement and limestone quarrying
Impact crushers (VSI): vertical shaft impactors
A vertical shaft impactor (VSI) uses a high-speed vertical rotor to throw material outward at high velocity, where it strikes a fixed anvil ring or rock-lined chamber wall and breaks on impact. This high-velocity impact produces a highly cuboid, well-shaped product with a predictable particle size distribution.
VSI crushers are primarily used at the tertiary or quaternary stage for manufactured sand production, fine aggregate shaping, and producing very fine aggregate fractions. Feed grading is critical: VSIs work best with a controlled, relatively uniform feed, and wear rates depend significantly on feed size and rock abrasivity.
Typical specifications and performance
- Feed size: typically 40–75 mm maximum — smaller than compression crushers at the same stage
- Throughput: 50–500 t/h depending on rotor size and speed
- Rotor tip speed: typically 50–75 m/s
- Product characteristics: excellent cubicity, well-suited to concrete aggregate standards
- Applications: manufactured sand, fine aggregate production, glass sand, industrial minerals
How VSI crushers are modelled in Quorr
In Quorr, a VSI crusher is placed at the tertiary or quaternary stage of the flowsheet. The simulation models throughput and the product gradation shift resulting from high-velocity impact, producing the characteristic VSI product with high proportions of material passing finer sieve sizes in a single pass.
Selecting the right crusher type for each stage
Primary crushing
Use a jaw crusher for most hard rock primary applications. Use a gyratory crusher where throughput exceeds 1000–1500 t/h. Use a primary HSI for soft to medium-hard rock (limestone, chalk) where product shape is a priority and wear cost is acceptable.
Secondary crushing
Use a cone crusher for hard, abrasive rock. Use a secondary HSI for softer rock with higher product shape requirements. The secondary stage typically runs in closed circuit with a screen.
Tertiary crushing
Use a fine-chamber cone for hard rock tertiary reduction. Use a VSI where product shape and cubicity are critical, or where manufactured sand production is needed.
Application matters most
Rock type, target product size, product shape requirements, and throughput all influence crusher selection. Model each option in Quorr to see the impact on throughput and product quality for your feed material.
Simulate any crusher type in Quorr
Quorr supports jaw, cone, and impact crusher types in its plant simulation environment. Each crusher type uses its own performance model, so the simulation reflects how that type of crusher behaves in the circuit.
You can mix crusher types in the same plant design. A typical three-stage plant might include a jaw primary, a cone secondary in closed circuit, and a VSI tertiary for product shaping. Quorr models the full circuit with each crusher contributing its own throughput and gradation calculation.
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Frequently asked questions
What is the difference between a jaw crusher and a cone crusher?
A jaw crusher uses two jaw plates in a reciprocating motion to break rock by compression. It is used primarily at the primary stage for large, coarse feed. A cone crusher uses a gyrating mantle inside a concave bowl for continuous crushing, used at secondary and tertiary stages for finer product with tighter size control. Jaw crushers handle larger feed sizes; cone crushers produce finer, more uniform product.
What is the difference between an HSI and a VSI impact crusher?
An HSI (horizontal shaft impactor) uses horizontal rotor-mounted blow bars to strike material and break it by impact. It is used for primary and secondary reduction of softer, less abrasive rock. A VSI (vertical shaft impactor) uses a high-speed vertical rotor to throw material against an anvil ring, producing cuboid product. VSIs are primarily used for manufactured sand and fine aggregate shaping.
Can you use a jaw crusher for secondary crushing?
It is uncommon. Jaw crushers have a fixed crushing geometry optimised for coarse primary feed. At the secondary stage, a cone or impact crusher is better suited because it can accept the smaller, more uniform feed from primary crushing and produce a finer, more controlled product.
What types of rock suit each crusher type?
Jaw and cone crushers are designed for hard, abrasive rock: granite, basalt, gabbro, quartzite. HSI crushers suit soft to medium-hard, less abrasive rock: limestone, chalk, sandstone, demolition material. VSI crushers are effective across a range of rock types where product shape and fine sizing are the priority, but wear rates increase with harder, more abrasive materials.
How do I choose between crusher types for my application?
The key factors are rock type, feed size, target product size and shape, and required throughput. Building a plant simulation in Quorr with different crusher type options for the same feed and production target is a practical way to compare performance before making a selection.