Benefits of VSI

• Mines can increase production when faced with limited capital
• When mines have a small Orebody that cannot support a high cost crushing system
• They will achieve better liberation from a marginal Orebody
• They will crush finer within the existing budgets
• They will increase / accelerate milling rate through existing grinding mills
• Reduces energy usage
• Reduces downtime
• The VSI can handle a large range of feed sizes of graded material
• High “through the rotor” tonnages eliminating the use of cascade
• Product grading can be changed by varying speed of rotors
• The shape of the finished product which is typically more cubical and uniform than a cone crusher product

VSI Crushers have the lowest running cost of any competitive crusher on the market in specific applications where high moisture forms part of the feed.

It was in response to the requirements of the African conditions that Orecrusher took it upon themselves to manufacture the Orecrusher Vertical Shaft Impactor Crusher. This product is a crushing machine used in the reduction of a wide range of materials and minerals to a consistent and uniform consistency.

The Orecrusher VSI is robust and durable and has been designed using the latest technology, and manufactured to the highest standards to withstand the arduous duties to which it is generally applied whilst achieving unrivaled performance.

How does a VSI work?

The crushing principle of this vertical shaft impactor (VSI) is that of using an impeller or rotor that is centrally fed from above to accelerate the feed or particles to a great speed. These particles are then flung into an open void – being the crushing chamber. This is done at very high speed and at a sufficient feed rate to enable the crushing chamber to fill up with a large amount of high speed material rebounding in all directions. This suspended material is constantly being impacted by more material from the rotor. When the crushing chamber is full of suspended material, the crushed particles then start to escape via a discharge chute immediately below the rotor and crushing chamber.

As a result of this action, the crushing chamber forms a natural build-up of hard packed material around the outer wall of the crushing chamber. When the crusher is in full operation, this retained material forms an almost vertical wall of stone upon which the pumped stone impacts and breaks down. Further reduction is made by the constant flow of new material from the rotor into this already violent mass of suspended material.

The overall result of this unique type of crusher is a consistent, regular grade of well-shaped product.

This crushing action is extremely violent and very effective on most types of material and gives a very uniform and consistent grade of product. The amount of reduction depends upon several factors, all of which may be varied to some degree.

These are as follows:

• Feed Size, Type and Grade of Material
• Feed Rate (in tons per hour)
• Rotor Speed, Size and Number of Ports
• Crushing Chamber Size, Type
• Cavity Tuning Ring Size, Type and Number
• Power: Single or Dual Drive (from 70kw to 440kw)

As the leading manufacturer of equipment for the Vertical Shaft Impactors (VSI) industry in South Africa, Orecrusher brings you uniquely designed Orecrusher Rotors to complement and enhance the usage of your VSI. Orecrusher Rotors can be retrofitted to most brands of VSIs with only minor modifications.

Orecrusher’s expertise in this industry in the African market is unrivalled and through regular research and development, we have designed the Orecrusher Rotor to ensure that, no matter the application, it:

• increases production up to a guaranteed 25% for the same installed power
• reduces wear costs
• reduces energy usage
• reduces downtime
• reduces maintenance costs

In order to make use of the Orecrusher Rotors, they are designed to eliminate the need for rebalancing, hard facing and removal from machine to replace wear parts.

With Orecrusher Rotors, there is no need whatsoever for a rotor bypass system, such as cascading to artificially increase the crushing capacity. We do not recommend cascading in high-reduction applications.

Orecrusher’s fit-for-purpose Orecrusher Rotors are available in many sizes and configurations in order to meet the exacting needs for applications in the quarrying, mining and mineral markets.

There is many criteria that have to be considered when you’re selecting suitable rotors and wear parts that will match the requirements of your application. They are:

• Initial required throughput. (50 tph-350tph)
• Feed sizes, both single and graded
• Closed circuit feed
• Hardness of material
• Elongation of material
• Moisture content of material
• Required product
• High reduction
• Shaping
• Differential crushing
• Liberation

Contributing to the comprehensive solution offered by Orecrusher, we bring you quality crushers and refiners for various applications. Refiners are specifically created to address contaminant-related wear that can affect critical equipment in the mining and quarrying industries.

Over 82% of internal wear and damage in equipment is a result of contaminants in lubricants (The Canadian National Research Council). It was in an effort to address these problems that Orecrusher decided to include oil refiners and diesel filters in its product offering.

We are an ISO accredited supplier, reflecting our commitment to maintaining optimum quality standards that are required by the African market.

Orecrusher’s refiners are made to be user friendly and easy to maintain, eliminating unnecessary struggles and ensuring continuous and efficient operation, even when faced with extreme and harsh conditions.

Orecrusher’s oil and diesel refiners are all made in-house.

Oil refiners are designed to remove all solids and semi-solids above 2 micron from oil. It removes dirt, but it does not remove additives or affect the properties of the lubricant and also re-establishes the lubricant cleanliness levels. The result is less internal wear on your machinery. Contact us for more information on Orecrusher’s Oil Refiners.

Diesel Refiners also remove all solid and semi-solid particles above 2 micron. It eliminates contaminants from diesel that could cause serious wear and damage on fuel systems, resulting in cleaner fuel. By doing this, it notably prolongs the life expectancy of fuel injectors and diesel pumps. Contact us for more information on Orecrusher’s Diesel Refiners.

By utilizing our casting and machining resources, Orecrucher extends our professional service to our slurry pump division. We manufacture new pumps, refurbish existing units and supply wear parts and components, from our well stocked ware house. Orecrusher, in collaboration with Extreme Slurry (Pty) Ltd are able to cater and supply all your pumping requirements.

Orecrusher designs and specifies all ancillary equipment supporting the crushing circuit. Orecushers capability extends to the design and supply of high standard feeders and feed chutes, conveyors static magnets and wet and dry screens.