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Impact Crusher VS Hammer Crusher: Differences and Choices
As key equipment for mining, impact crushers and hammer crushers share the responsibility of crushing stones of different sizes, and continuously supply the required stones for infrastructure construction and other industrial fields. Faced with these two excellent crushing equipment, many users who are seeking to purchase may be confused: which one is better? What are the differences between them? Next, Smat Machine will discuss and answer these questions in detail.
Differences in working principles
The working principle of the impact crusher is very similar to that of the hammer crusher. They both use high-speed impact to crush materials, with slight differences.
How does a hammer crusher work?
The working principle of the hammer crusher is that the ore is initially crushed under the action of the high-speed rotating hammer head, and then rebounds and hits the impact plate at high speed to achieve further crushing. In this process, the ore will be crushed multiple times.
How does an impact crusher work?
The working principle of the impact crusher is that the material first collides with the rotating hammer head, and then rebounds to the impact plate at high speed. The crushed material flies at high speed in the tangential direction to the impact plate at the other end of the crushing chamber and is crushed again. In this way, a piece of stone will undergo multiple crushing processes in the impact crusher.
Compared with the hammer crusher, the impact crusher has the following differences:
(1) The plate hammer and rotor of the impact crusher are rigidly connected, and the inertia of the entire rotor is used to impact the material, so that it is not only crushed but also obtains a larger speed and kinetic energy. The hammer head of the hammer crusher is a single hammer that impacts and crushes the material, and the speed and kinetic energy obtained by the material are limited.
(2) The crushing chamber of the impact crusher is larger, so that the material has a certain amount of space to move, and the material is fully crushed by the impact. The crushing chamber of the hammer crusher is smaller.
(3) The plate hammer of the impact crusher greets the input material from the bottom up for impact crushing and throws it onto the upper impact plate. The hammer crusher hits the material along the direction of the material falling.
(4) Impact crushers generally do not have a grate screen at the bottom, and the product particle size is determined by the speed of the plate hammer and the gap between the plate hammer and the impact plate or leveling grate plate. The grate screen controls the product particle size of the hammer crusher.
Impact Crusher vs Hammer Crusher – 10 Differences
The working principle is the main difference. In addition, there are ten other differences between impact crusher and hammer crusher.
| Comparison Dimension | Impact Crusher | Hammer Crusher |
|---|---|---|
| 1. Structural Design | – Rotor with multiple impact plates; independent, adjustable rebound plate. – Open-type crushing chamber without grizzly bars. |
– Rotor with closely spaced hammerheads; fixed grizzly bars at the bottom. – Closed-type chamber, with discharge controlled by grizzly bar gaps. |
| 2. Crushing Mechanism | – Multi-stage impact crushing: Materials are struck by impact plates, then rebound for secondary collisions. – Ideal for large lump materials. |
– Single-stage impact crushing: Hammerheads directly strike materials, relying on collisions between materials and chamber liners. – Suited for fine or medium crushing. |
| 3. Particle Size Control | – Adjusted via rebound plate angle or replacement. – Produces uniform, cubic particles. |
– Controlled by grizzly bar gap adjustment. – Prone to elongated or flaky particles; requires secondary screening. |
| 4. Material Suitability | – Handles high-hardness, coarse materials (e.g., iron ore, quartz). – Tolerates higher moisture content (no grizzly bars to clog). |
– Limited to medium-low hardness, brittle materials (e.g., limestone, coal gangue). – Clogs easily at >15% moisture. |
| 5. Wear Parts | – Impact plates: High-chrome cast iron or composite alloys; quick replacement (single-side disassembly). – Rebound plate made of high-manganese steel or composites. |
– Hammerheads: Manganese steel or composite wear-resistant materials; requires full rotor disassembly for replacement. – Grizzly bars wear quickly, needing frequent replacement. |
| 6. Capacity & Energy Consumption | – High capacity (up to 2000 t/h), but higher energy consumption (multiple impacts). | – Lower capacity (typically <800 t/h), lower energy use (simpler design). |
| 7. Maintenance Ease | – Quick impact plate replacement (1–2 hours downtime). | – Complex hammerhead replacement (rotor disassembly required); higher maintenance costs. |
| 8. Product Shape | – High cubic particle ratio (>80%), minimal needle/flake particles. | – Higher flaky content (~30%); requires secondary shaping. |
| 9. Safety Features | – Hydraulic flip-up cover or quick-access design for easy maintenance. | – Simpler structure but requires entry into the chamber for repairs, posing safety risks. |
| 10. Typical Applications | – Mining (coarse/medium crushing), construction waste recycling, manufactured sand production. | – Fine crushing of soft materials (e.g., limestone), coal processing, gypsum pretreatment. |
Next Page: Which crusher is best for crushing wet coal?
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