When the term “cone crusher” comes to mind, it’s often associated with the brutal task of crushing high-hardness materials like granite, basalt, and iron ore. While this is its primary function, a cone crusher’s efficiency, superior product shape, and high-volume capacity make it a surprisingly versatile machine. It can be a very effective solution for processing certain low-hardness minerals, particularly when producing a high-quality, cubical aggregate is a top priority.

Why Use a Cone Crusher for Softer Materials?

While impact crushers or hammer mills are also common for softer materials, a cone crusher offers distinct advantages that make it a compelling choice for specific applications:

• Superior Product Shape: The compressive crushing action of a cone crusher produces a more uniform, cubical product compared to other methods. This is highly desirable for construction materials and certain industrial applications where particle shape is critical.
• High Throughput: Cone crushers are built for continuous, high-volume production. When processing softer materials, their speed and capacity allow for immense productivity, making them ideal for large-scale operations.
• Reduced Fines Generation: The crushing principle of a cone crusher is designed to minimize the production of unwanted fines or dust, ensuring that the final product meets specific grading requirements. This can lead to a more valuable end product and less waste.
• Durability and Reliability: Although the material is soft, a cone crusher’s robust design means less wear and tear, even with high throughput, leading to lower maintenance costs and greater uptime compared to impact-based crushers that can see significant wear on their blow bars and hammers.

Specific Low-Hardness Minerals for Cone Crushers

Here are some of the most common lower-hardness minerals where a cone crusher excels in secondary and tertiary crushing stages:

Limestone (Mohs hardness 3)

Limestone is a very common sedimentary rock widely used in construction, cement production, and as an agricultural soil amendment. While jaw crushers and impact crushers are also used, a cone crusher is an excellent choice for limestone because it can produce large quantities of high-quality cubical aggregate for concrete and asphalt. It efficiently takes a coarser limestone feed and sizes it precisely, all while minimizing flat or elongated particles that can weaken a concrete mix.

Gypsum (Mohs hardness 2)

Gypsum is a soft sulfate mineral used to produce plaster, drywall, and fertilizer. In the gypsum production process, after primary crushing, a cone crusher is often used for fine crushing. Its ability to create a consistent, fine product is perfect for preparing the material for subsequent grinding and calcining stages. The low fines generation is a key advantage, helping to maintain material purity.

Coal (Mohs hardness 1-2)

Coal is a combustible sedimentary rock used primarily as a fuel source. While roll crushers and hammer mills are very common, a cone crusher can be used in certain coal processing applications to achieve a specific final size for power plants or other industrial uses. While not a primary use, its ability to produce a uniform product with minimal fines can be beneficial for specific types of coal.

Conclusion

While known for its strength against hard rock crushing, the cone crusher should not be overlooked for its ability to efficiently process low-hardness minerals. Its superior product shape, high-volume capacity, and durability make it a highly versatile piece of crushing equipment. For projects involving materials like limestone, gypsum, or even coal, a cone crusher offers a reliable and profitable solution, ensuring that the final product meets the highest standards for both size and shape.