The Benefits of Using Vertical shaft impact crusher

The Uses of a VSI Crusher

A VSI crusher, or to give it its full name, a vertical shaft impact crusher, can be used for most crushing applications. The principal uses will be in quarries and gravel pits to produce products for roads and asphalt, ballast, manufactured sand for concrete and aggregates for use in the construction industry. But VSIs are also used for the recycling of building material, namely concrete and asphalt and the processing of steel slag. Increasingly in a conservation-conscious world, industries must learn to recycle used materials instead of dumping them. And this in itself can be a profitable industry if they are processed properly with the right machinery.

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VSIs are commonly used to manufacture high quality aggregates used to build bridges, buildings, and tunnels for example. VSI crushers are a crucial part of producing manufactured or crushed sand. Nowadays extraction of natural sand is limited and sand is a scarce resource on earth. To meet the demand for sand, more and more needs to be manufactured or crushed.

With this type of crusher, the raw material starts its journey from the feed hopper. It enters the rotor through a central entrance. At this point, the raw material is projected from a spinning table with impellers to the outer circle equipped with anvils. As the name implies, the VSI crusher spins on a vertical axis. Once inside the crusher, the aggregate feed is projected against anvils and crushed by impact into smaller parts. The aggregate feed may be moving at speeds of up to 60-75 meters per second at this point.

Benefits of Using a VSI Crusher

Why choose a VSI crusher, as opposed to a compression crusher?

The VSI gives you several benefits:

• Versatile and Efficient: Able to process a wide range of materials – rock, clinker, concrete, asphalt, minerals – VSI crushers are particularly suited for demanding sectors such as construction and road-making.
• Simple to Run: The VSI is a solid piece of machinery. Its robust design ensures easy installation and minimal maintenance.
• Energy-efficient: High output with low energy use makes it a sustainable option for high-volume production.
• Durable: The build-up of rock inside the crusher creates a natural protective layer, reducing wear. The use of calibrated rolling bearings improves the shaft’s stability, enhancing reliability and lowering upkeep.

Maintenance is also simplified thanks to the modular design of wear parts. The main components—such as anvils, rotor tips, and wear plates—are easy to access and replace. Combined with the durability of ceramic-enhanced parts, this leads to longer intervals between interventions.

Our machines feature strategically positioned maintenance access points and automated lubrication systems that enhance operational safety. We also offer optional handling tools that simplify maintenance procedures, thereby increasing overall safety during interventions.

From a technical perspective, our high-chrome alloy used for anti-wear protection is a significant advantage. This premium-quality alloy substantially reduces part failures, which in turn decreases maintenance frequency and associated risks. The exceptional durability of these components directly translates to enhanced workplace safety – fewer interventions mean reduced exposure to potential hazards.

Choosing the Right VSI Crusher

At Magotteaux, we offer multiple VSI crusher models to meet your operational needs. The best model for your business will depend on:

• The required throughput
• The size and abrasiveness of your input material
• The specific particle size and quality you aim to produce

Our range includes the Mag’Impact® , and , each designed for different production capacities and feed sizes. Whether you need a compact unit for a recycling site or a high-capacity solution for a quarry, our experts will guide you to the most suitable machine.

And beyond the machine itself, choosing the right partner to supply your VSI. Consider the following before finalizing any understanding:

• What kind of pre-sale service does the company provide? Can you get the advice you can trust?
• Can you also get after-sale service if you need it?

In addition, we support you with integration into your complete production line. From upstream feeding systems to downstream screening, Magotteaux assists you in aligning your VSI crusher with your overall plant design for optimal material flow, reduced bottlenecks, and maximum output.

Magotteaux Produces Quality VSI Crushers

Magotteaux is your trusted partner when it comes to VSI crushers. With several types available, our team can recommend the right one to fit your firm’s needs. Whether you work in aggregates, recycling, or mining, we have a solution to suit your process and your materials. Our team will help you select the right crusher and configuration based on your objectives.

Contact us straight away to start a discussion about your company and your present needs with Magotteaux.

We don’t just supply machines – we develop them. Magotteaux’s R&D team works continuously on innovations in wear resistance and crushing performance, using advanced simulations and patented materials. The result? VSI crushers that not only last longer, but also perform more efficiently and sustainably.

Why Do Mining Companies Turn to Magotteaux For Our VSI Crusher Expertise?

Among other sectors, mining industry companies frequently choose Magotteaux for our VSI crusher expertise due to our deep understanding of the industry’s needs and our unwavering commitment to excellence. We have a proven track record of providing high-quality VSI crushers and wear parts that optimize performance and extend service life in this particular sector. Our dedicated team of engineers and technicians leverages their extensive knowledge and experience to develop innovative solutions tailored to each customer’s unique requirements. Furthermore, our global presence and a strong network of service centers ensure that we provide assistance to mining companies everywhere, helping to reduce downtime while maximizing productivity. At Magotteaux, mining companies can expect a seamless experience, from initial consultation to after-sales support. We are dedicated to helping our clients achieve their operational goals while minimizing the operational costs associated with mining and enhancing overall efficiency.

What Makes Our VSI Crusher R&D so Useful to Our Customers?

Here at Magotteaux, our relentless focus on research and development (R&D) enables us to provide customers with cutting-edge VSI crusher technology. Our R&D efforts are driven by our commitment to addressing industry challenges, improving wear life, and enhancing product performance. Our R&D team works closely with customers to identify their needs and develop tailored solutions that maximize efficiency while bearing down on costs. We invest in continuous improvement, utilizing simulation, advanced materials and patented designs to create VSI crushers and wear parts that offer superior longevity, not to mention resistance to everyday wear and tear. By choosing Magotteaux’s VSI crushers, customers benefit from a range of technological advancements. In turn, this will typically lead to lower maintenance costs and, therefore higher profitability. Our R&D initiatives ensure that our products remain at the forefront of the industry, delivering tangible benefits to our clients in every industrial sector.

How Does Our VSI Crusher Technology Support Sustainability?

Environmental impact is no longer an afterthought—it’s a priority. That’s why Magotteaux’s VSI crushers are designed with sustainability in mind. Our VSI crushers are designed to minimize energy consumption, for example. This allows our cutomers to make a contribution in reducing their greenhouse gas emissions and lowering their carbon footprints when utilizing our products. We also focus on reducing waste production by extending wear part life and minimizing the need for frequent replacements. Our advanced materials and patented designs contribute to improved wear resistance, leading to a decrease in raw material consumption and waste generation. Magotteaux is dedicated to promoting sustainable practices and resource efficiency in the mining and other industries serverd. By choosing our VSI crushers, customers are not only investing in cutting-edge technology but also contributing to a more sustainable future.

Safety: Beyond Industry Standards

At Magotteaux, we understand that durability and safety are intrinsically linked.

Our VSI crushers go beyond industry safety standards by focusing on this critical relationship-fewer maintenance interventions mean reduced exposure to workplace risks. This approach delivers clear economic advantages as well: reduced downtime translates to fewer potential injuries and a more satisfied workforce.

The exceptional durability of our high-chrome alloy components doesn’t just save money; it creates a safer working environment where teams spend less time on repairs and more time on productive operations.

We prioritize the safety of your team above all else, designing our equipment with the understanding that the best safety feature is equipment that requires minimal intervention.

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What Is VSI?

All roads, you might say, lead to the Vertical Shaft Impactor (VSI) because these crushers make it possible to create roadways and just about everything else. Francis E. Agnew of California patented one of the first Vertical Shaft Impactors in . His configuration stacked three VSIs atop each other to produce sand, thus starting the VSI evolution.

Today, VSI crushers – and the folks who rely on them – have produced many configurations to include everything from the addition of cascading material into the crushing chamber, to air swept separation of lighter product. One version suspends the shaft from above like a sugar centrifuge. It’s also one of the most feature-patented crushers, so some of the things mentioned here might be unique to a single manufacturer. VSIs apply a large amount of energy to crush material and that’s why it’s one of the most versatile crusher configurations today.

View our VSI Machine Specifications, and get a quote today!

VSI Benefits

When it comes to producing materials such as aggregate for road making, VSI crushers use a high-speed rotor and anvils for impact crushing rather than compression force for the energy needed for size reduction. In a VSI, material is accelerated by centrifugal force by a rotor against the outer anvil ring, it then fractures and breaks along natural faults throughout the rock or minerals. The product is generally of a consistent cubical shape, making it excellent for modern Superpave highway asphalt applications. The rotor speed (feet per minute) controls final particle size.

The VSI’s high cubical fracture percentage maximizes first-pass product yield and produces tighter particle size distribution. It has a high-throughput capacity ideal for beneficiation (elimination of soft material). Properly configured the VSI accepts highly abrasive materials. It has simple operation and maintenance. You can quickly change product size by changing rotor speed or cascade ratio. Some models have reversible wear parts to reduce downtime. The VSI typically has low operating costs even in high-moisture applications because of reduced energy costs and low wear cost per ton.

VSI Disadvantages

There are some feed size limitations with a VSI because of the small feed area available in the center of the rotor. Tramp material in the feed such as gloves, tools, etc. can cause problems with imbalance. The high RPM and HP require careful balance maintenance such as replacing shoes on both sides of the rotor at the same time. High wear part cost may be a problem for some hard abrasive materials, but the VSI may still be the best option.

VSI Applications

Major limestone applications are for Superpave asphalt aggregates, road base, gravel, sand and cement. Industrial uses include: corundum, corundite, ferro silicon, glass, refractories, silicon carbide, tungsten carbide and zeolite. Mining applications include: bauxite, burnt magnesite, iron ore, non-ferrous metal ore, perlite and trona sulfate. VSIs are excellent for everything from abrasive materials to waste and recycling applications.

VSI Crushing Method

The VSI is typically used after a primary or secondary crusher. This makes a VSI ideal for making sand and for making coarse and medium aggregates for concrete/asphalt production.

Feed size and characteristics will affect the application of a VSI. The feed size is limited by the opening in the center of the rotor. Normally less than 5-inch material is desired, but very large VSIs can handle up to 12-inch feed. Another feature that will affect application is moisture, which can make the feed sticky. Required production capacity is the final limiting criteria. Large primary horizontal shaft impactors can output up to TPH and more. TPH is about the maximum for a VSI because of the limiting motor size and the rising G-force of a high-speed rotor, which is calculated by multiplying the radius times the square of the RPM.

Shoe configurations are many: rock on rock, groups of rollers, special tip wear parts and many others. The metallurgy of the shoes is also highly varied. Rotors can have three to six shoes. The number of shoes is typically governed by the diameter of the rotor. The larger the diameter rotor, the more openings are possible. Computational Fluid Dynamics (CFD) mathematical models are utilized to simulate the flow and collision forces to reveal solutions for lower wear cost, consistent final product, and higher energy efficiency.

The material to be crushed is fed into the center of an open or closed rotor. The rotor rotates at high rpm, accelerating the feed and throwing it with high energy into the crushing chamber. When the material hits the anvil ring assembly, it shatters, and then the cubical shaped product falls through the opening between the rotor and the anvil and down to the conveyor below.

The rotor speed (feet per minute) controls final particle size. Speeding up the rotor will produce more fines, slowing it down will produce fewer fines.

The VSI features multiple rotor/anvil configurations for various applications. From open or enclosed rotors to the tubular rotor, each machine is configured for their unique application. In many cases the rotor table, rotor assemblies, anvil ring or rock shelf are interchangeable, allowing maximum application flexibility.

Open top metal rotor shoe on metal anvil

The open top metal rotor is good for large feed or medium to very hard material, but it will work best for softer materials. It can handle medium abrasive, dry or wet, but not sticky materials. High reduction ratios are common, which are excellent for sand and gravel production in closed loop systems. Shoe shape can change the production size range. A straight shoe face design produces finer product, and a curved shoe face design produces coarser material.

Tubular metal rotor shoe on metal anvil

The tubular rotor creates higher tip-speeds, which increases first pass yield with tighter particle size distribution and also reduces the recirculation loads. One unique feature is that the rotor rotation is reversible, allowing wear on both sides of the tube. Rotating the tube itself one-quarter turn also doubles the wear.

Enclosed metal rotor shoe on metal anvil

The enclosed top plate on a rotor primarily prevents material from escaping from the top of the rotor, which could happen with an overfed open top rotor.

(Above: Rock shelf when VSI at rest. In operation, the brown rock fills the chamber to the upper roof ring. Rock impacts rock in operation.)

Enclosed autogenous rock rotor table on autogenous rock shelf

Any time the material or rock is used as an impact wear surface the term autogenous is used. Putting a top on the rotor table and shoes allows autogenous use. During operation of the VSI, a bed of material can be designed to build up inside the rotor against each of the shoe wall segments. The bed, which is made up of material that has been fed to the rotor, extends to a wear tip. The bed protects the shoe wall segment from wear.

Concerning the rock shelf anvil, it forms a near vertical wall of material upon which the accelerated material impacts. “Rock-on-rock” crushing reduces maintenance but can require up to 30 percent of material recirculation before meeting size requirements. Also, the rock shelf anvil absorbs energy that could otherwise be used for breaking, which may reduce efficiency. More RPM may be needed to achieve the same result as a solid metal anvil.

Good for medium abrasive materials, rock-on-rock configurations of either or both rotor and anvil may produce consistent material with low-wear cost and can handle wet but not sticky conditions. Reduction ratios from 2:1 to 5:1 can be expected. It’s widely used for quarried materials, such as sand and gravel.

Due to the many configurations of the VSI feed, rotor, anvil and open- or closed- system design; testing is the only way to ensure proper application of a VSI crusher.

Summary

The VSI is one of the most versatile crushers available on the market today. Even with some limitations, like feed size and output capacity, VSI features have been and continue to be developed to maximize first-pass yields and lower operating costs. If you test your process on full-scale equipment before choosing your VSI, you won’t be disappointed.

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