Advantages And Disadvantages Of Four Different Crushing Plant

The production of open-pit mines cannot work without crushing equipment. Adopting appropriate stone crushing plant can effectively reduce the effectiveness of ore and rock transportation and improve production efficiency. Stone crushing plant in open-pit mines include mobile, semi mobile, semi fixed, and fixed types according to the degree of fixation between the crushing equipment and the foundation. This article shows the introduction and comparison of the advantages and disadvantages of four types of crushing stations. They are mobile, semi mobile, semi fixed, and fixed stone crushing plant.

Four Types Of Stone Crushing Plant

Mobile crushing plant

Generally, the mobile crushing plant integrates feeding, crushing, and conveying. The walking adopts track type or tire type (there are also stepping type). We can adjust the position at any time with the movement of the working face in the mining area.

Advantage:

Replace dump trucks and reduce procurement costs.
Cut down transportation costs by 50% to 70%. Lower spare parts, labor costs. Reduce maintenance of the mining site road surface.
It has the characteristics of both safety and environmental protection. Because it is a three in one device and the continuous transportation equipment connected to it is a belt conveyor. The tracked mobile crushing station is more suitable for large open-pit mines for large-scale and continuous mining processes.

Disadvantages:

The equipment is complex, expensive, and the one-time investment is too large, making it difficult for the mine to afford economically.

Semi mobile crushing plant

The semi mobile crushing station, also known as a modular unit. It is a device that places the machine body at a suitable working level in an open-pit mining area. With the advancement and extension of the working steps, the crushing unit is transported as a whole (or in parts) by tracking transport vehicles or other traction (pulling) equipment.

A modular unit consists of three main parts: crushing, screening, or feeding equipment. Non standard design and manufacturing components such as steel structure supports, hoppers, and buffer silos. The standard design and production components include three steel grating platforms, italics, handrails, and railings.
The most typical feature of a semi mobile crushing station is that it is not connected to a concrete foundation on the ground. Its service life ranges from several months to several years. The migration time usually does not exceed 48 hours.
The difference between semi mobile crushing plant and mobile crushing plant lies in the time of relocation and the location of equipment layout. Semi mobile crushing plant are usually shows on the working side of the mining area, and at positions where the ore and rock transportation distance is less than 3km. When the mining area steps extend beyond the reasonable transportation distance and climbing height of the truck, carry out the next relocation.

Advantage:

It not only has the advantage of being mobile, but also overcomes the disadvantages of semi fixed plant construction and long relocation time:

Overall design and supply: The main equipment, non-standard steel structures, and standardized components such as walkways and escalators are designed as a complete set, saving time and effort for the owner, and ensuring fast and efficient construction and installation.
Short construction period: This machine can be pre assembled in the factory. Shipping and disassembled to the project site for quick assembly after eliminating installation faults. Each component is connected by bolts, almost without on-site welding, which is conducive to rapid construction and production.
More reasonable investment: less civil engineering work, no need for concrete construction above ground level. Low labor intensity, higher proportion of equipment and steel structure investment in total investment, and steel structure still has high residual value after a long time.
Capable of mobile transition, It is free to go to another location for reinstallation and use, but the transition frequency requires not too high.

3. Semi fixed crushing plant

The semi fixed crushing plant is a transitional mode from a semi mobile crushing plant to a fixed crushing plant. From the perspective of connection with the ground, the crushing frame has a strong connection with the ground. From the perspective of layout, it is generally stays on the fixed side of the mining site to minimize the frequency of relocation and improve the service life. Especially for rock crushing and transportation, which is particularly important.

Advantage:

Due to its solid foundation, the semi fixed crushing plant is suitable for large-scale operation in mines with large processing capacity, with a long service cycle.

Disadvantages:

To build a fixed foundation, the construction period is long, the amount of relocation work is large, the relocation operation time is long, and the civil engineering cost is high.

4. Fixed Crushing Plant

The fixed stone or sand crushing plant are usually stays outside the boundary of the mining area, or set up inside the mining area in conjunction with the chute. They are not affected by the deepening of the mining area steps and permanently connect to the ground. After completion, they will stays in one place permanently without moving. The feeding method has diversity, which can be directly unloaded by vehicles, or equipped with buffer silos for feeding by ore drawing devices. Fixed crushing stations are generally located in the crushing workshop of the beneficiation plant and have the same service life as the mine.

Disadvantages:

Its biggest disadvantage is that the ore transportation distance is long, the transportation cost is high, and it is not suitable for reasonable adjustment.

Comprehensive analysis

The mobile crushing station is self-propelled in terms of its walking ability, with typical walking modes including tire type, track type, and step type; From the layout position, it is generally located on the mining face and needs to move flexibly as the mining face advances.
The semi mobile crushing station does not have walking function and needs to be transported as a whole or separately using specialized moving tools without connecting to the ground. Sled crushing stations are also included in this category. From the layout position, it should be placed on the working or non working side, and as the steps descend and the distance of the car increases, it should be moved to a suitable position below.
The semi fixed crushing station has a clear connection with the ground, and the crusher needs to be installed on an effective concrete foundation or steel structure. In the layout, it should be placed on a fixed support. Of course, there are also some examples where, due to the limitations of terrain and geological conditions, a more sturdy foundation needs to be built on the working support to place the crusher, which is also included in the semi fixed crushing station.
Fixed crushing stations are the least controversial in terms of classification, have a solid foundation, are used for extended periods of time in the mining area, have a relatively solid transportation distance, and are not suitable for adjustment.

Eastman is a professional mining equipment manufacturer with 38 years of rich experience in the mining construction industry. We can also provide lab equipment. Welcome to consult our professional team to get factory prices. According to your situation and product requirements, we will design a complete sand-crushing production line flow chart and provide an accurate quotation.