This practical guide compares jaw and cone crushers for hard rock. It explains principles, key specs, operating metrics, and real SBM project cases. Read on for clear selection advice, measured data, and actionable maintenance steps.
A jaw crusher uses a moving jaw to compress rock against a fixed jaw. It works by single-toggle or double-toggle action. A cone crusher uses an eccentrically rotating mantle inside a concave bowl. The cone creates a continuous compression, and particle breakage occurs by inter-particle crushing. Both are compression machines, but they target different stages of comminution.
Jaw: main parts include frame, eccentric shaft, flywheel, and jaw plates. Typical reduction ratio is 1:2 to 1:3. Nip angle normally sits 16–23 degrees. Closed side setting (CSS) mainly controls product size. These crushers run at low speed and use large torque.
Cone: main parts are mantle, concave, eccentric, bowl, and hydraulic setting. CSS/OSS (open side setting) define the minimum and maximum gap at the crushing zone. Speed and stroke, combined with chamber profile, set the throughput and shape. Modern cones balance speed, throw and cavity design to raise inter-particle crushing.
Key specs: feed size, product size, feed gradation, throughput (t/h), motor power (kW), rotor speed (rpm), reduction ratio, and wear life. Energy per tonne is critical; energy may vary with CSS and material abrasiveness. For hard, dense rock, cone crushers often give better particle shape and finer product for the same circuit. Jaw crushers excel as primaries for large boulders.
Energy and wear: laboratory and field studies show jaw crushers use variable energy depending on feed gradation. Cone crushers are more energy-efficient in secondary/tertiary stages when set correctly. Typical preventive maintenance windows follow an hours-based schedule: daily checks, weekly greasing, monthly inspection, and major overhaul at roughly 2000 operating hours. Faults often stem from ungraded feed, lubrication faults, and liner failure.
Primary jaw: feed up to 800–1200 mm for large models; product typically 50–200 mm depending on CSS. Secondary cone: feed up to 200–300 mm; product ranges from 5–50 mm depending on chamber and CSS. These ranges align with standard crushing flows used in hard rock operations. Always match crusher class to crusher stage.
Step 1: define stage. If primary coarse reduction is needed choose jaw. Step 2: if secondary or tertiary shaping choose cone. Step 3: match feed size and required product with CSS and chamber. Step 4: check motor match and power margin (allow 10–20% spare). Step 5: validate with test crushing or pilot run. This simple flow reduces risk and improves predictability.
Match motor kW to duty. For primary jaws the motor must deliver high torque at low rpm. For cones the motor supplies steady power at higher rpm. Oversizing wastes energy; undersizing causes slugging or trips. Use soft-start drives and torque monitoring for hard rock circuits.
Below is representative plant data from SBM test runs with hard granite feed. Values vary by model and feed grading.
| Unit | Feed size (mm) | Throughput (t/h) |
|---|---|---|
| Jaw XH-PE900x1200 | 800 | 220 |
| Cone XH-HPC220 | 200 | 320 |
CapEx varies with model, duty, and site works. Opex drivers are energy, wear parts, and downtime. For hard abrasive rock, wear parts are the main recurring cost. A correct selection reduces wear and saves operating expense. ROI improves if the circuit lowers tertiary crushing needs by one stage.
Install on level concrete pad. Align drive, check base bolts and soft-start wiring. Commission with graded feed not exceeding rated maximum. For maintenance follow a checklist: daily lubrication, weekly liner inspection, monthly vibration check and annual gearbox and eccentric inspection. Spare parts stocking reduces downtime.
Case A — Mountain granite quarry, Jiangsu province. Problem: Blocky, high-strength granite created frequent secondary crushing needs. Solution: SBM supplied XH-PE1200 primary jaw plus XH-HPC300 cone in closed circuit with screen. Design lowered tertiary needs, increased throughput by 18% and reduced fines content. Outcome: Installation took 14 days, first month average throughput 480 t/h, wear parts life improved 22%. Client feedback: easier maintenance, stable feed, and lower total cost per tonne.
Case B — Aggregate plant, Fujian coastal site. Problem: Corrosive humid climate, hard basalt feed. Solution: SBM provided corrosion-coated XH-PE900 and XH-HPC220 with hydraulic setting and automated lubrication. Results: uptime rose to 95% and energy per tonne fell by 9% in six months. Client comment: fast commissioning and clear maintenance schedules; staff found daily checks simple.
A jaw cannot match cone shape or consistent fine sizing in secondaries. Use jaw for coarse primary crushing. Then, use cone for sizing and shape. Mixing stages is common practice.
Frequency depends on abrasiveness. Typical liner life ranges from 500 to 3000 hours. Monitor wear and schedule changes during planned shutdowns. Keep spares on site.
Adjust CSS to optimal setting, maintain correct feed gradation, use high-efficiency motors and VSDs, and avoid over-crushing. Regular lubrication reduces internal losses.
Use material work index, abrasion index, and pilot tests. Apply energy-per-tonne and wear-cost-per-tonne metrics. Additionally, compute payback for improved product quality. These metrics give objective decisions.
For hard rock primary reduction choose a robust jaw crusher. For secondary/tertiary shaping choose a cone crusher. Choose motor sizing carefully. Plan maintenance and stock wear parts. Validate selection through pilot trials. SBM offers matched circuits, field-proven designs, and local after-sales support.
1) What is ideal CSS for hard granite? — Start at manufacturer recommended CSS and reduce in 0.5 mm steps while monitoring power and throughput. 2) Can we run wet sticky feed? — Pre-screen and use flow aids; both crushers tolerate some moisture but blockages increase. 3) Do you provide commissioning? — Yes; SBM provides on-site commissioning and operator training.
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