Mobile crushing plant

Types of mobile crushing plants

Mobile crushing plants are built-in combinations of many different types of crushing plants and other processing plants. The mobile crushing plant is a fully movable, integrated processing system for the aggregates industry.

• Mobile Primary Jaw Crushing Plant:

The primary task of the mobile jaw crushing plant is to crush large-sized stones and rocks into smaller, more manageable pieces. This is achieved by employing powerful jaws that exert significant force on the materials, breaking them apart. Once crushed, the mobile jaw plant then screens the fragmented materials to separate undesirable materials. The screened materials are subsequently forwarded to other processing units for further refinement and processing.

• Mobile Secondary Cone Crushing Plant:

The mobile cone crushing plan's main task is to screen crushed materials that have undesirable constituents within them. Once the screening process has been completed, the undesirable materials are separated and removed from the production line. The remaining screened materials are forwarded to the mobile cone crushing plant. The cone crushing plant has the primary responsibility of further crushing the already screened materials into finer particles. These final products may then be utilized in various construction projects or sold as aggregate materials.

• Mobile Secondary Impact Crushing/Sieving Plant:

The mobile secondary impact crushing/sieving plant utilizes an impact crusher within its system. Impact crushers function by employing a high rotor speed that throws the material against the anvils, resulting in the crushing process. The sieving process takes place after the material is crushed by the impactor. This separation procedure involves classifying the crushed material according to its size. Subsequently, the undesired fractions are sent away, while the desired fractions are forwarded to other processing units for further handling and utilization.

• Mobile Tertiary Crushing/Sieving Plant:

Mobile tertiary crushing/sieving plants are a type of crushing and screening equipment that plays a crucial role in aggregate production. These plants are designed to handle the final stages of crushing and sieving, yielding high-quality aggregate materials suitable for various construction applications. The primary crusher in mobile tertiary crushing/sieving plants is typically a vertical-shaft impact crusher. This type of crusher operates by introducing the material from the top through a centripetal rotor. The rotor accelerates the material, projecting it outwards into the crushing chamber, where it undergoes further reduction. The sieving process is then carried out to separate the desired fractions from the undesired ones.

It is also helpful to know that quarry mobile crushing plants break down larger base stones into smaller stone aggregate types. Road mobile crushing plants generally spread out and crush base stones in specific locations on the road construction. Concrete mobile crushing plants usually involve a closed-circuit configuration that enables the reuse of the water of the concrete in the system.

Specification and Maintenance of Mobile Crushing Plant

Specification

Some specifications of mobile stone crushing plants are as follows:

• Weight

  The weight of a mobile crushing plant varies based on the components, configurations, and models. Its weight may range between dozens and hundreds of tons.

• Overall Dimensions

  The overall dimension includes length, width, and height. The overall dimensions of a mobile crushing plant also differ based on its type and model. Take the mobile jaw crusher plant for an example. Its length may be about 16m, the width is about 3m, and the height is about 4.3m.

• Power

  The power of a mobile crushing plant also differs based on its type and model. Generally, crushing plants are equipped with diesel generators, electric motors, or power units. The power may range from 100kw to several thousands of kw.

• Production Capacity

  The production capacity or crushing capacity of a mobile crushing plant indicates how many tons of materials it can process in one hour. The numbers vary according to the model and the type of the crushing plant. For instance, the production capacity of a mobile jaw crusher plant may range from 50 to 400 tons per hour.

Maintenance

A mobile stone crushing plant requires regular maintenance to ensure stable performance and efficient operation. Here are some mobile crusher maintenance tips:

• Check the fasteners of the entire mobile crushing plant regularly. Make sure the fasteners are steady and firmly connected. Supplement and tighten them if necessary.
• The service life of the tracks largely depends on their maintenance. Therefore, operators should inspect the wear of the tracks frequently. Adjust the track tension to avoid damages. Replace the track at once if there's any noticeable track wear or damage.
• Formulate a regular lubrication plan according to the manufacturer's instructions. It ensures the plant is well-lubricated and reduces the friction and wear of components.
• Conduct regular inspections of hydraulic systems. Check hydraulic hoses, pumps, and cylinders for wear, tear, or leakage. Fix any issues that may arise promptly.
• Mobile crushing plants are usually equipped with cooling systems. Ensure the cooling system works properly over time. Maintain optimal working temperatures by regularly checking coolant levels and cooling fans.
• Operators should establish a maintenance schedule for mobile crushing plants. Follow the maintenance timetable according to the manufacturer's instructions. It may include regular repairs, parts replacements, and equipment adjustments.

Scenarios of mobile crushing plants

Mobile crushing plants are vital pieces of equipment in the construction and mining industries. They have versatile applications in various fields, such as:

• Mining: Mobile crushing plants are used for mining operations by large-scale mineral extraction companies to directly process valuable ore at the site. This eliminates the need for transporting low-grade rock to processing facilities. By separating useful minerals such as gold, copper, and cobalt from the surrounding rock, mobile crushers reduce expenses and boost extraction efficiency.
• Urban demolition and recycling: A growing number of cities are opting for mobile crushing plants instead of fixed plants to reduce pollution from dusty emissions. Mobile crushers allow urban demolition projects to quickly process materials on-site, lessening air pollution from material transport. Mobile crushers also enable the recycling of construction waste into reusable aggregates and reduce environmental landfill use.
• Road and bridge construction: Road and bridge construction projects frequently need to crush materials such as granite, basalt, limestone, concrete, and asphalt on-site, which calls for mobile crushing equipment with flexibility and rapid setup capabilities. Mobile crushing plants can efficiently process raw materials like asphalt concrete produced during road and bridge repairs into high-quality aggregate by eliminating the need for complicated transportation logistics and extended preparation times.
• Land reclamation: Land reclamation projects involve converting bodies of water such as lakes, rivers, and seas into usable land. Mobile crushers facilitate this by processing seabed materials like coral, granite, and limestone into aggregates for the construction of dikes, embankments, and other structures. Mobile crushing plants allow engineers to reclaim land efficiently without the need for fixed crushing facilities.
• Hydraulic engineering: Mobile crushers are well-suited for hydraulic engineering projects, which involve the management of water through activities such as dam and channel construction, flood prevention, and drainage. These large-scale endeavors often take place in remote locations far from urban centers. Mobile crushing plants provide an on-site solution by eliminating the need for extensive transportation of aggregate or rock that needs to be processed.
• Agricultural development: Mobile crushing plants have applications in the agricultural sector as well. They can assist in land preparation for farming by processing excess rock or stone that impedes cultivation. Mobile crushers facilitate the establishment of new farmland by transforming agricultural land.

How to Choose Mobile Crushing Plants

• Demand Analysis:

  Business buyers should first determine the overall crushing capacity and target materials that the mobile plant must prioritize. Examining the project scope can highlight essential features like the required stone sizes for specific projects.

• Compatibility with Feed Material

  Business buyers must ensure that the plant's configuration matches their materials. Factors like raw material type, size, and hardness influence equipment selection.

• Production Capacity

  Business buyers must choose a mobile plant with the right production capacity to meet their project's demands without incurring excessive costs. The plant's configuration will determine the estimated production capabilities.

• Flexibility and Scalability

  Consideration of future project needs may encourage business buyers to seek adaptable, scalable solutions. Modular systems and adjustable equipment can efficiently respond to fluctuating production requirements.

• Advanced Technology

  Some mobile plants offer intelligent features that enhance efficiency and productivity. These may include automation, real-time monitoring, and remote control capabilities.

• Operating and Maintenance Costs

  Business buyers should assess long-term expenses, including fuel consumption, wear parts, and maintenance requirements. Selecting an efficient, low-maintenance plant can significantly reduce operating costs.

Q&A

Q1: What is the difference between a mobile crushing plant and a portable crushing plant?

A1: The primary difference between a mobile and a portable crushing plant lies in their capacity and flexibility. Mobile crushing plants offer more flexibility and adaptability to various locations than portable ones. Portable plants, designed for easier transportation, are more suited for projects where the location won't change frequently.

Q2: Can a mobile crushing plant crush any material?

A2: No, not every mobile crushing plant is designed to crush all types of materials. Different types of plants are built to handle specific materials. For example, some are made for hard rocks, while others are suited for asphalt or concrete.

Q3: What are the latest trends in mobile crushing plant technology?

A3: Recent developments in mobile crushing plants include stronger, lighter materials for easier transportation, hybrid power systems for fuel efficiency, and advanced automation and control systems for improved efficiency and safety.

Q4: What is the lifespan of a mobile crushing plant with proper maintenance?

A4: With proper maintenance, a mobile crushing plant can have a lifespan of 10 to 15 years. Some components may need to be replaced or upgraded after 5 to 7 years for optimal performance.

Q5: What are the environmental impacts of mobile crushing plants?

A5: Mobile crushing plants can contribute to air pollution, noise pollution, and disturbance to local wildlife. However, they can reduce environmental impacts by minimizing material transportation and incorporating recycling capacities.