The crusher plant plays a vital role in various construction and mining operations. The piece of equipment can transforms large rocks into manageable aggregates, which are crucial for creating the concrete, asphalt, and other materials that form the backbone of modern infrastructure.
However, do you know how crusher plant works? Which kind of crusher equipment used in the plant? And How do they achieve the finial crushing result? Find these answers in the following introduction.
How Many Types of Crusher Plants in The Market?
When it comes to the types of crusher plant available in the market, they can broadly be classified into two main categories according to the mobility of plant crusher. One is the stationary crushing plant and the other one is mobile crushing plant. Next, I will introduce you their characteristics, advantages, and applications in different industrial environments, which can guide you select a suitable type of crusher machine plant for your projects.
Stationary Type Crusher Plant: 30tph-1000tph
Firstly, the stationary crushing plant represent a traditional and commonly used type of crusher plant. In general. it is installed at a specific location. And it is very suitable for long-term operations and large-scale mining and construction projects that require consistent, high-volume processing. It includes a fully stationary crusher plant and a semi-stationary crusher plant.
Compared with the mobile-type crusherplant design, the fixed plant crusher machine has no mobile tires and crawlers. Althouth with the technology development of equipment, the stationary crush plants is always clients’ primary choice.
- Fully stationary crusher plant. It is usually fixed in a specific place. In most cases, it is located on the surface of the open-pit mine, and some are located at the bottom of the open pit. The fully fixed crusher plant for sale is the type which is mainly adopted before the 1980s. It needs a long construction time and high cost. Besides, with the extension of the mining range, the transport distance will increase, and the car freight will also increase.
- Semi-fixed crusher plant. It is usually composed of crushers, belt conveyors, and other equipment, and its height is about 30m. When the whole set of plant crusher machine needs to be moved to a new location, every part needs to be dismantled, and the individual part is transported by the carrier and reassembled in the new location. In general, the location period is about 10 years, and the transfer work will take about a few weeks.
Mobile Type Crusher Plant: 30tph-450tph
Mobile crushing plant offers greater flexibility and mobility. It can be easily transported from one job site to another. Thus, it is appropriate for projects that require frequent relocation of the crushing operation.
Moreover, the mobile crusher plant machine has saved significant time and costs associated with material transportation and setup. The mobile crusher plant for sale can adapt to a variety of site conditions. Thereby, clients consider it as the preferred choice for short-term projects and operations spread across different locations.
APY4-4660S Mobile-type Crusher PlantCapacity: 16-40(t/h)
- Feeder model: APG-3090W
- Production capacity(t/h): 16-40
- Primary crusher model: APJ-4060E
- Transport Length(mm): 15500
- Secondary crusher model: APC-600Y
- Transport width(mm): 2800
- Vibrating screen model: APS-1237Y
- Transport height(mm): 4200
- Weight(t): 41
| Model | APY4-4660S | APY4-4690S | APY4-57110S | APY4-6912S |
|---|---|---|---|---|
| Feeder model | APG-3090W | APG-3090W | APG-3090W | APG-3896W |
| Primary crusher model | APJ-4060E | APJ-4060E | APJ-5070E | APJ-6090E |
| Secondary crusher model | APC-600Y | APC-900Y | APC-110C | APF-1214 |
| Vibrating screen model | APS-1237Y | APS-1548Y | APS-1848Y | APS-1848Y |
| Tire configuration | Parallel three shafts | Parallel three shafts | Parallel three shafts | Parallel three shafts |
| Return belt conveyor model | B500 | B650 | B800 | B1000 |
| Feeder belt conveyor model | B500 | B650 | B00 | B1000 |
| Under-sieve belt conveyor model | B650 | B800 | B1000 | B1200 |
| Production capacity (t/h) | 16-40 | 16-65 | 50-100 | 60-160 |
| Transport length (mm) | 15500 | 16500 | 16500 | 16500 |
| Transport width (mm) | 2800 | 2850 | 2950 | 2950 |
| Transport height (mm) | 4200 | 4200 | 4200 | 4200 |
| Weight (t) | 41 | 45 | 53 | 50 |
Superior Advantages of Mobile Crushing Plants
Aimix mobile-type crusher plants has adopted advanced production technology and design concepts to cater to different clients’ crushing demands. Check its advantages below.
- The installation form of the entire set of equipment can not only eliminate the installation of complex site infrastructure but also reduce material loss and time loss. The reasonable and compact space layout of the set of equipment can improve the flexibility of site stationing.
- This kind of crusher plant equipment is flexible and the car chassis is high, so it is convenient for moving on the ordinary highway and the rugged road in crushing areas. It saves time for stationing at the construction site. Moreover, the mobile stone crushing machine is easier to locate in a reasonable construction area, and it provides more flexible space and reasonable layout configuration for the overall crushing process.
- The whole set of portable crushing screening plants can work individually or work together by combining flexibly on the basis of coarse crushing and fine crushing.
- The crusher plant machinery can greatly reduce transportation costs because materials need not be transported to the next process location remotely. All the machines used in the whole process are in the same place.
- Unloading hopper also has some excellent features. In addition to providing the flexibility of diverse configurations for material delivery, the unloading of the hopper can also supply power to the processing system specifically.
The stationary crushing plant and mobile cresar plant can cater to the diverse needs and operational requirements of various projects. The choice between these two types of crusher plants depends on different factors, such as the scale of operation, feed material characteristics, project logistics, etc.
How to Design Crusher Plant
Designing an efficient crusher plant involves a comprehensive process that considers various factors. Here are the key steps in the crusher plant design process.
Before starting the design process, it’s crucial to understand the project’s goals and requirements:
Determine the crusher plant capacity, amount of material to be processed per hour/day.
Analyze the properties of the raw material (hardness, abrasiveness, moisture content, etc.).
Define the desired size and type of the final product.
Choose the appropriate type of crusher (jaw crusher, cone crusher, impact crusher) based on the feed material characteristics and the desired product size distribution.
Determine the size, capacity, and specifications of the primary crusher and any secondary or tertiary crushers required.
Select auxiliary equipment, such as feeders, conveyors, screens, and material handling systems, to support the crushing process.
Develop a detailed layout plan that optimizes the material flow, crusher plant equipment list placement, and overall plant efficiency.
Consider factors such as material handling distances, equipment accessibility, maintenance requirements, and future expansion possibilities.
Incorporate necessary infrastructure, including foundations, power supply, water management systems, and access roads, into the layout design of crusher plant drawing.
Design the material flow process, including the feed material receiving, crushing, screening, and final product storage or transportation.
Determine the appropriate conveyor systems, transfer points, and material handling equipment to ensure efficient and smooth material movement throughout the plant.
Optimize the material flow to minimize bottlenecks, reduce energy consumption, and enhance overall productivity.
Following the above tips, the AIMIX engineers can create a customized and efficient crushing solution that meets the specific requirements of the project. Here are some customized solutions designed by us for reference.
Customized Crushing Solutions for Clients
250T/H Stationary Crusher Plant For Crushing Basalt
This configuration is intended to break basalt rock. Basalt is a very hard type of rock, therefore, this crusher plant near me was outfitted by our specialist with a jaw crusher and a compound cone crusher.
- Raw materials used: basalt
- Production capacity: 250t/h
- Finished product requirements: 0-10-20mm
The Specific Configuration Is As Follows:
APY2-750J Jaw Type Crushing Plant + APY2-200C Cone Type Crusher Plant
Please do not hesitate to send us a message if you need a stationary crusher plant price. Besides, we also have mobile-type crusher plants solution, check it below.
200T/H Aggregate Mobile-type Jaw Crusher With Screen
There are two mobile-type crusher plants used in this configuration, which can provide more convenience to projects that require frequent transshipment.
- Maximum feed size: ≤600mm
- Production capacity: 200t/h
- Finished product demands: 0-24mm
The Specific Configuration Is As Follows:
APY2-750J Jaw Type Crushing Plant + APY2-200C Crusher Plant Cone
Above is a solution we designed for customers from Malaysia. Please do not hesitate to send us a message if you want to get a mobile crusher quote.
How Does A Crusher Plant Work?
The crusher plant working mainly include several steps, such as feeding, crushing, screening, convenying, etc. You can check the process.
Step 1: Feeding the Raw Materials
The process begins with the feeding of raw materials into the crusherplant. Large rocks, stones, or other materials are loaded into a hopper using excavators or loaders. The hopper funnels these materials into the primary crusher.
Step 2: Primary Crushing
In the primary crushing stage, the large materials are reduced to smaller, manageable sizes. The primary crusher, usually a jaw crusher or gyratory crusher, applies mechanical pressure to break down the raw materials. This initial crushing process reduces the size of the materials to make them suitable for further processing.
Step 3: Screening and Sorting
After primary crushing, the materials are transported to a vibrating screen. The screen separates the crushed materials based on size. Oversized materials are returned to the primary crusher for further reduction, while appropriately sized materials move on to the next stage.
Step 4: Secondary Crushing
The secondary crushing stage further reduces the size of the materials. Cone crushers or impact crushers are typically used in this stage. These crushers refine the materials into finer aggregates, ensuring they meet specific size requirements for different construction applications.
Step 5: Tertiary Crushing (If Necessary)
In some cases, a tertiary crushing stage is required to achieve the desired material size and shape. Tertiary crushers, such as vertical shaft impact crushers(VSI crushers), finely crush the materials, enhancing their quality and uniformity.
Step 6: Conveying and Storing
Once the materials have undergone the necessary crushing stages, they are conveyed to storage areas or directly to the project site. Conveyor belts or trucks transport the final aggregates, ensuring they are readily available for use in construction projects.
From feeding raw materials to delivering final aggregates, each stage plays a critical role in producing high-quality construction materials. You can watch the following crusher plant video to clearly understand the process.
If you need other questions about crushing plant working, contact us directly through the inquiry form, tel and email! AIMIX engineers will reply to you in 6 hours.