The mobile crusher plants are efficient solutions for various industries that require on-site or near-site processing of raw materials. Thus, it can significantly reduce material transportation costs, enhance production efficiency, and offer more flexible operations.
Nowadays, the mobile crusher plant is widely used in mining, construction waste recycling, and the production of sand and gravel aggregates. Indeed, it is an advanced and efficient equipment configuration that integrates crushing, screening, and conveying. First, let’s delve into how does it works.
There is a gif picture that has shown the general working process of a crushing plant. It can help you better understanding the working principle.
Are you clear about it after viewing the process? Next, I would also explain it in detail. The working principle of the mobile crusher plant can be summarized in the following steps:
Feeding Material
The feeder uniformly conveys the raw materials into the crusher host’s inlet. The feeding speed and quantity need to be adjusted according to the crusher machine’s processing capacity to ensure stable feeding. There are two kinds of feeders, include vibrating feeders, belt feeders, etc., which need to be selected based on the characteristics of the raw materials.
Crushing Process
Primary Crushing
Large rocks and raw materials are transported and fed into the primary crusher, which reduces them to a manageable size. Generally, the jaw crusher, impact crusher, and gyratory crusher are used the primary crusher. You need to choose the suitable one according to your crushing demands.
Secondary Crushing
The output from the primary crusher is conveyed to the secondary crusher, which further reduces the material size. Secondary crushers can include cone crushers, impact crushers.
During the crushing process, the core equipment of the mobile crusher plant, responsible for crushing large raw materials into the required size. Common types of crusher equipment include jaw crushers, impact crushers, cone crushers, etc., each with different crushing characteristics and applications.
Screening Process
The crushed materials are then graded by the vibrating screens. The qualified product particles are screened out, while the oversized or undersized particles are returned to the crusher for further processing.
Classifies and screens the crushed materials to obtain products of different particle size specifications. In general, AIMIX mobile crushing plants are equipped with vibrating screens. If you need other kinds of screens, we can customize it for you.
Conveying Process
The various product particles are transported by belt conveyors to the designated silos or stockpile areas. The convenying belt is responsible for transporting materials among feeder, crusher and screener. The width, speed, and other parameters of the conveyor belts need to be optimized based on the actual material conditions.
Electric Controlling
The system ensures the coordinated and efficient operation of the entire mobile crusher plant by monitoring and adjusting the various components as needed.
If you want to know the working process more vividly, please check the following working video:
While the underlying principles of mobile crushing plants are similar across different industries, there are some notable differences in the work processes based on the specific requirements and characteristics of mining, construction waste recycling, and sand and gravel aggregate production industries.
Differences in Work Processes in Various Industries
Mobile crushing plants have been applicable in a range of industries. However, the working processes of it can differ significantly depending on the industry and the specific requirements of the materials being processed. Next, you can explores how mobile crushing and screening plants are adapted to meet the unique demands of various industries.
Crusher Types and Configurations
The choice of crusher type and the configuration of the mobile crushing plant are crucial factors that vary by industry and material characteristics.
For example, in mining or construction waste recycling, the mobile crusher plant may be equipped with more robust crushers to handle harder or more abrasive materials, while in sand and gravel aggregate production, it may be optimized for efficient processing of the raw materials to ensure a well-graded final product suitable for construction applications.
Feedstock Preparation
In mining and sand and gravel aggregate production, raw materials are typically extracted directly from natural deposits. These materials often require minimal preparation before being fed into the mobile crushing station. For example, in a mining operation, ore might be blasted and then directly loaded into the crusher. Similarly, in aggregate production, raw gravel might be scooped from a riverbed and processed with little pre-treatment.
Conversely, in construction waste recycling, the feedstock may require more extensive pre-processing, such as sorting, removal of contaminants, and size reduction, to ensure the efficient operation of the mobile crusher plant.
Product Requirements
The end-use of the processed materials dictates specific product requirements. It can influence the configuration and operation of mobile crushing plant.
In the construction industry, the production of high-quality aggregate with a specific particle size is crucial for creating durable concrete mixture. Therefore, mobile crushing plants need to include secondary crushing, screening, and washing processes to meet these stringent specifications. And in the recycling sector, the focus might be on producing clean, uniform recycled aggregates that can be used as a substitute for natural materials.
The working processes of mobile crushing stations are tailored to meet the distinct demands of different industries. If you want to configure a mobile crushing solution, welcome to consult us for details.
Preparations Before Mobile Crusher Plant Operation
Before starting a mobile crushing plant, several steps should be taken to ensure smooth and efficient operations at the construction sites.
Site Preparation
- Site selection: Identify a suitable location for the mobile crushing and screening plant that provides adequate space for equipment setup, material stockpiling, and vehicle movements.
- Clear Site: Clear the site of any debris, vegetation, or obstructions that could interfere with the equipment or pose safety risks.
- Ground Grading: Grade the ground surface to create a level, stable foundation for the stone crushing plant.
- Drainage: Establish proper drainage to prevent pooling of water around the equipment.
Equipment Inspection
- Inspect Components: Thoroughly inspect all components of the mobile crushing plant, including the crusher, conveyors, screens, and power systems. Check for any signs of wear, damage, or malfunctions and address any issues before starting operations.
- Check Safety Devices: Ensure all safety guards, emergency stops, and other protective devices are functioning properly.
- Top Up Fluids: Top up all fluid levels, such as engine oil, hydraulic fluid, and coolant, as per the manufacturer’s recommendations.
Connections
- Power Supply: Secure a reliable power source, either from the grid or a dedicated generator, to power the mobile tracked crusher plant. Ensure proper electrical connections are made and that the power supply is compatible with the equipment’s requirements.
- Water Supply: If required, establish water supply connections for dust suppression systems or other plant operations.
Safety Measures
- Training: Provide thorough training for operators and workers on the safe operation of the mobile crushing station.
- Safety Equipment: Ensure the availability and use of safety equipment such as helmets, gloves, and ear protection.
- Emergency Procedures: Establish emergency procedures for accidents or equipment failures.
Proper preparation and planning are crucial to the successful deployment and operation of mobile crushing plants on-site. Each step is crucial for maximizing productivity and efficiency on the job site.
If you’re in the market for a reliable mobile crushing solution, welcome to reach out us. With years of experience in the industry and a wide range of mobile crusher plant models to choose from, we can help you find the perfect equipment to meet your unique project requirements. Contact us now through the following inquiry form!
