What Is the Difference Between a Mineral Sizer and a Crusher
A mineral sizer is a medium-to-fine crushing device based on the principle of intermeshing tooth roll crushing. It represents a modern crushing approach that produces final products with good particle shape. Our company provides both primary and secondary mineral sizers capable of processing a variety of materials ranging from soft coal to hard rock.
A crusher is a mechanical device that uses mechanical forces such as compression, impact, shear, and grinding to reduce large solid materials into smaller particles. Crushers are widely used in mining, metallurgy, building materials, chemicals, coal, and other industries. Their core function is to reduce material size to meet the requirements of subsequent processing, transportation, or direct use.
A crusher is a general term for machines that reduce large materials into smaller sizes, whereas a mineral sizer is a specific type of crusher designed to handle hard rock and other minerals, with a focus on minimizing fines and maintaining consistent product sizing.
From a definitional standpoint, mineral sizers and crushers are different. Below is a more detailed comparison between the two.
I. Types
Crushers come in a wide variety of types. They can be categorized by crushing principle (e.g., compression crushers, impact crushers, grinding crushers), by material (e.g., ore crushers, wood crushers), by mobility (e.g., stationary crushers, mobile crushers), and by output size (e.g., coarse, medium, and fine crushers). Each type operates based on a different crushing mechanism.
In contrast, the mineral sizer has a unique design: it consists of two inward-rotating toothed rolls, each equipped with replaceable crushing teeth. The material is fed evenly at a controlled rate and distributed uniformly across the rolls.
II. Working Principle
The mineral sizer operates with two inward-rotating toothed rolls. The mineral is gripped between the leading edges of the opposing rotor teeth and subjected to stress under the concentrated load of the teeth. This stress causes the mineral to fracture along its natural grain structure. The material is broken through a tensile fracture mechanism between three points of contact—between the front tooth of one rotor and the rear tooth of the other. Materials that are not fully broken are further crushed by fixed teeth located on crushing bars, ensuring the final product meets three-dimensional sizing requirements.
Crushers, depending on the type, utilize different crushing methods. For example, jaw crushers crush through compression and bending, hammer crushers use impact and grinding, while cone crushers use lamination crushing.
III. Materials and Applications
Crushers can handle a wide range of materials with varying hardness—from soft to extremely hard. Mineral sizers also have substantial processing capabilities, particularly well-suited for dry or wet hard materials. However, they are not ideal for highly abrasive materials, as this can lead to rapid wear of the crushing teeth.
Crushers are widely applied in aggregate production, construction, and mining to reduce the size of rocks, ores, and other materials. Mineral sizers are specialized for processing hard rock minerals like iron ore, copper, and gold. Therefore, while crushers are general-purpose, mineral sizers are tailored for specific mineral applications.
IV. Performance Comparison
Crushing Ratio: The crushing ratio varies significantly among different types of crushers. Coarse crushers such as jaw crushers have a low crushing ratio (3–6), while fine crushers like impact crushers can reach ratios above 50. Mineral sizers typically have a moderate crushing ratio, usually between 3–10, making them suitable for medium or fine crushing with uniform output granularity.
Processing Capacity: Large crushers like cone crushers can handle several thousand tons per hour. Mineral sizers, on the other hand, have relatively lower throughput and are more suitable for medium or small-scale production lines, or specific processing steps such as pre-blending fine crushing.
Energy Consumption & Wear: Crushers processing high-hardness materials consume more energy, and wear parts such as jaw plates and hammers wear out quickly. Mineral sizers, with their low-speed rotation and concentrated force application, have relatively low energy consumption. However, their teeth are prone to wear when handling hard materials and require regular replacement or resurfacing.
Environmental Considerations: Mineral sizers are more environmentally friendly due to their enclosed structure design, which produces less dust. Their crushing process generates less vibration and lower noise levels. In contrast, some crusher types, like hammer crushers, produce significant dust and require additional dust suppression systems.
V. Conclusion
The mineral sizer is a specific type within the broader category of crushers. While crushers cover the full range of crushing needs, the mineral sizer focuses on medium to low-hardness material, emphasizing medium-to-fine crushing and uniform output. With its “toothed roll crushing” mechanism, the mineral sizer is designed for low energy consumption, minimal dust, and consistent product size. In contrast, general-purpose crushers are better suited for high-hardness materials or high-capacity scenarios.
