CI Series Impact Crusher
1. Introduction: Solving Shaping and Throughput Challenges in Modern Quarries
In modern infrastructure, highway construction, and high-strength concrete batching, aggregate quality standards have evolved drastically. Traditional crushing circuits that rely solely on compressive breaking often yield elongated, flaky particles with excessive internal micro-cracks. These sub-optimal aggregate shapes compromise concrete strength and consume excess asphalt binder.
Furthermore, processing mid-hard rocks—such as limestone, dolomite, sandstone, and gravel—requires secondary crushing machinery that delivers high reduction ratios without excessive energy consumption or complex mechanical adjustment procedures.
The CI Series Impact Crusher is engineered specifically to overcome these bottlenecks. Built with an optimized crushing chamber, massive high-inertia rotor, and advanced hydraulic adjustments, the CI Series serves as an industry-standard solution for secondary and tertiary crushing, delivering superior particle cubicity and operational reliability.
2. Technical Parameter Matrix & Engineering Ratings
The CI Series incorporates finite element analysis (FEA) into its structural design to maximize crushing kinetics, durability, and throughput. Below is the technical breakdown across the series envelope:
| Specification Metric | Engineering Rating | Process & Operational Value |
|---|---|---|
| Crusher Class | CI Series Secondary Impact Crusher | High-energy impact reduction with selective crushing action |
| Max Feeding Size | 300–500 mm | Accepts run-of-quarry rock and primary jaw discharges directly without pre-scalping bottlenecks |
| Discharge Size Range | 0–35 mm (adjustable) | Produces tightly graded, highly cubic finished aggregates (<31.5 mm and <20 mm) |
| Throughput Capacity | 120–380 t/h | Engineered for commercial quarries processing 1,500 to 4,500 tons per day (TPD) |
| Installed Motor Power | 132–250 kW | High torque and energy transfer efficiency per ton of processed material |
| Rotor Configuration | Heavy-duty solid / open rotor | Maximum rotational momentum and kinetic energy transfer upon high-velocity impact |
| Curtain / Apron System | 2 to 3 adjustable impact aprons | Multi-stage expansion chamber providing precise reduction ratio and shaping control |
| Hydraulic System | Hydraulic frame opening & apron setting | Facilitates fast apron gap adjustments, safe tramp clearing, and quick blow bar replacements |
3. High-Inertia Rotor Dynamics & Superior Product Cubicity
The heart of the CI Series is its optimized, heavy-duty rotor assembly. Fabricated from high-tensile forged steel and dynamically balanced, the rotor provides massive kinetic inertia even during heavy surge-feed conditions.
1. Selective Impact Fracture: Material entering the chamber encounters high-velocity blow bars. Breakage occurs along the natural geological cleavage lines of the rock, eliminating internal stress fractures and generating clean, cubic stones with low flakiness indexes (<10%).
2. Multi-Chamber Crushing Action: The primary apron handles severe initial impact reduction, while the secondary and optional tertiary grinding aprons refine aggregate grading. This progressive reduction achieves single-stage ratios of up to 20:1.
3. Optimized Blow Bar Locking: The wedge-clamping system locks high-chrome blow bars tightly against the rotor face under centrifugal and impact forces, preventing loosening during operation while simplifying removal.
4. Hydraulic Integration: Safety, Speed, and Minimal Downtime
Maintenance accessibility directly influences crushing plant uptime and profitability. The CI Series eliminates laborious manual turnbuckle adjustments and mechanical jack setups:
• Hydraulic Housing Opening: Two heavy-duty hydraulic cylinders open the split upper frame smoothly in minutes, giving service technicians clear, uninhibited access to blow bars, side liners, and impact plates.
• Hydraulic Apron Setting (CSS Control): Operators can adjust the clearance between the blow bar tips and the impact aprons via external hydraulic switches or integrated control panels, compensating for blow bar wear without halting the plant for hours.
• Overload & Tramp Protection: When uncrushable tramp metal enters the chamber, the hydraulic assist system cushions the impact aprons, allowing them to retract momentarily and discharge the obstruction before automatically resetting to the preset clearance.
5. Flowsheet Integration: Closed-Circuit Quarry Layout
The versatility of the CI Series allows seamless integration into secondary aggregate crushing lines and manufactured sand preparation plants:
Closed-Circuit-Aggregate-Crushing-Flowsheet-CI-Series-Secondary-Circuit
In this closed-circuit flowsheet, the CI Series replaces multi-stage secondary cone crushers and tertiary vertical shaft impactors (VSI) in soft-to-medium-hard stone applications, lowering both total plant capital expenditure (CAPEX) and complex conveyor network requirements.
6. Wear Parts Optimization & Maintenance Protocols
Maximizing wear part service life is essential for maintaining low operating cost per ton (OPEX):
• Blow Bar Metallurgy: Choose High-Chrome Martensitic Steel for abrasive limestone and sandstone, or Ceramic-Insert Blow Bars for extended service life in high-wear abrasive applications.
• Turn & Flip Schedule: The symmetric design of the blow bars allows them to be flipped 180 degrees to utilize both striking edges, doubling usable wear volume before replacement.
• Liner Protection: The chamber interior is protected by interchangeable, bolt-on high-manganese side liners, preventing structural housing erosion from abrasive dust turbulence.
7. Frequently Asked Questions (FAQ)
Q1: What types of rock are best suited for the CI Series Impact Crusher?
A: The CI Series excels in soft to medium-hard rock formations with compressive strengths up to 200 MPa, such as limestone, dolomite, gypsum, sandstone, and non-abrasive gravel. It is also widely used in concrete demolition waste and asphalt recycling.
Q2: How does the CI Series achieve better particle shape than a standard cone crusher?
A: Cone crushers crush rock through compression and shear, which can produce needle-like or flaky fractions in laminated rock. The CI Series breaks rock via high-speed velocity impact and rock-on-metal collision, breaking the rock along natural grain boundaries to produce uniform, cubical aggregates.
Q3: What is the average service life of high-chrome blow bars in limestone crushing?
A: In standard, clean limestone applications with low silica content (<3%), a set of reversible high-chrome blow bars typically delivers 400 to 800 hours of service life per side (800 to 1,600 hours total with flipping).
Q4: Can the CI Series be mounted on a mobile or skid-mounted chassis?
A: Yes. The compact footprint and high power-to-weight ratio of the CI Series make it suitable for tracked mobile plants, wheeled semi-trailers, and modular steel skids for rapid deployment.
Q5: How does the hydraulic clearing system protect against machine damage?
A: If an uncrushable object enters the rotor trajectory, the impact aprons retract under hydraulic damping relief to pass the foreign body, then return to their original set points, preventing rotor deformation or main shaft deflection.
8. Summary & Next Steps
The CI Series Impact Crusher sets a high benchmark in aggregate reduction by combining a high reduction ratio (85−380 t/h), excellent product cubicity, and modern hydraulic maintenance interfaces. For quarry owners aiming to secure premium concrete and asphalt stone supply contracts, the CI Series delivers a competitive cost-per-ton advantage.
Ready to Optimize Your Aggregate Plant?
• Request a Custom Crushing Flowsheet: Contact our application engineers with your raw material sample and desired grading curves for a customized plant sizing model.
• Download Complete Technical Drawings: Access installation dimensions, dynamic foundation loads, and electrical hookup data.
Baichy Heavy Industry
Baichy Heavy Industry is a high-tech mining equipment company integrating R&D, manufacturing, sales, and after-sales service. Focusing on crushing, grinding, and mineral processing equipment, we provide professional solutions to our customers. We are ISO9001:2015 銆乧ertified, and our products include mobile crushing palnts, crawler crushing plant, construction waste crushing plants, jaw crushers, sand making machines, cone crushers, fine crushers, grinding mills, ball mills, etc., all with reliable performance to meet diverse project needs.
Baichy Heavy Industry – Your Trusted Partner
To ensure optimal performance of your equipment, Baichy Heavy Industry offers:
- Professional on-site installation guidance
- Comprehensive operator training
- 24/7 technical support & maintenance services
Our complete after-sales service system guarantees long-term, stable operation of your machinery with minimal downtime.
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