How to choose a crushing production line: fixed, mobile or semi-mobile?
In mining, crushing and mining equipment has a wide range of applications and plays an important role in the processing and treatment of various ores. Stone crushers can meet the needs of various industrial fields by crushing different types of ores.
Different types of ores require different crushing processes and equipment, so it is necessary to comprehensively consider factors such as process requirements, equipment parameters and quality requirements according to actual conditions to select suitable crushing equipment.
Crushing equipment can be divided into three types: fixed, mobile and semi-mobile. There is no absolute advantage or disadvantage in fixed crushing stations, mobile crushing stations and semi-mobile crushing production lines, only the degree of “scenario adaptability”.
This article will elaborate on these three types of crushing equipment, analyze their differences, and explain to you “how to choose” at one time.
Characteristics of three types of crushers
Fixed crusher: Crusher + feeding + screening + conveying are all made on a permanent concrete or steel structure basis. After completion, they will no longer move and have the same life as the mine/factory.
Mobile crusher: All main machines are integrated on tire or crawler chassis, which can be self-driven or towed by a tractor, and can be put into production on site.
Semi-mobile crusher (modular/sled type): The whole unit is placed on a reusable steel skid or modular frame, without a permanent foundation, and can be hoisted and transferred as a whole or in parts, and the relocation time is ≤48 hours
Fixed crushing equipment plant
Fixed crushing equipment requires construction of foundations, and the civil engineering and labor investment is large. These infrastructures are usually designed and built according to the size, weight and production capacity of the equipment. The site selection requirements are relatively high, and the site needs to be fully utilized for planning and layout. Once it is necessary to move to other places, the original infrastructure usually needs to be dismantled and rebuilt.
Fixed crushing equipment is usually used together with feeders, crushers, vibrating screens, conveyors and other equipment to form a production line to form a complete production system. Such a production line can be configured and adjusted according to the specific material crushing requirements and process flow to achieve efficient crushing and screening operations.
Mobile crushing equipment plant
Mobile crushing stations are divided into tire-type mobile crushing stations and crawler-type mobile crushing stations. Tire-type mobile crushing stations rely on semi-trailer heads for traction, and crawler-type mobile crushing stations adopt self-driving mode, which can realize on-site steering and can be driven onto trailers through wireless remote control to achieve rapid transfer. Mobile crushing stations do not require the construction of plant buildings or civil engineering foundations, which reduces the investment and time of engineering construction, avoids material transfer and reduces transportation costs, and has a short construction period.
Mobile crushing stations break through the limitations of site, environment, basic configuration and logistics. They can operate independently as a single unit, and can be combined with different models to form a powerful crushing operation line to complete multi-demand processing operations and improve overall work efficiency.
Mobile crushing stations can be configured with jaw crusher series, cone crusher series, impact crusher series, sand making machine and other crushers according to the customer’s requirements for material types and products in the process, providing more flexible process solution configuration to meet users’ various needs such as mobile crushing and mobile screening.
Semi-mobile crushing plant
Semi-mobile crushing station itself does not have the walking function and needs to rely on external equipment such as trailers or cranes, so it can be quickly relocated and transferred. Semi-mobile crushing station does not require tedious civil engineering operations, thus saving a lot of time and cost, shortening the project cycle and improving overall efficiency.
Semi-mobile crushing station is a multi-integrated frame structure solution consisting of one or several crushing and screening unit modules.
Semi-mobile crushing station is mainly used for the primary and secondary crushing and screening of medium and soft hardness rocks, construction waste, concrete blocks and other raw materials. It can be widely used in urban construction waste treatment, rock crushing in mining and tunnel construction.
Advantages and disadvantages of three types of crushing stations
Fixed type
Advantages: large-scale single machine, strong overproduction capacity; can be configured with multiple closed-circuit processes; environmental dust collection and noise reduction are centralized and managed in one go.
Disadvantages: long initial civil construction and construction application period (3-6 months); the distance of raw material transportation increases with the depth of the steps, and the long-term freight is high; the inability to relocate leads to low residual value.
Semi-mobile type
Advantages: taking into account both production capacity and mobility; civil construction volume ≈ 0; can help “move down step by step” in the mining site, and always maintain a car transportation distance of ≤3 km; the residual value of the steel structure is high.
Disadvantages: relocation still requires large crawler transport vehicles or lifting equipment; frequent relocation is not recommended (recommended ≥1 year/time).
Mobile type
Advantages: pull and go, complete the transfer in 1-3 days; no infrastructure approval is required; reduce 50-70% transportation costs and road maintenance.
Disadvantages: The size of the whole machine is limited, and the specifications of the main machine are relatively small; the chassis, hydraulics, and electronic controls are complex, and the purchase cost is 20-30% higher; the commonality of later spare parts is poor.
Crushing equipment purchase suggestions:
Determine the use scenario and needs: Consider factors such as the type of material to be processed, processing volume, working hours, production requirements and budget.
Define equipment specifications: Understand the equipment parameter information, including motor power, speed, number of strokes, and parameters such as the rotor diameter, speed and crushing cavity type of the crusher, to determine the appropriate equipment specifications and processing capacity.
Consider mobility requirements: If frequent transfers or temporary work are required, choose a mobile crushing station or a semi-mobile crushing station; if long-term stable operation is required, choose a fixed crushing equipment.
Understand the manufacturer and service: Understand the manufacturer’s reputation and after-sales service. A good manufacturer should provide comprehensive technical support and after-sales service to ensure the normal operation and maintenance of the equipment.
SMAT crushing manufacturers can provide on-site installation and after-sales maintenance services.
Consider cost-effectiveness: Comprehensively consider factors such as equipment price, operating cost, maintenance cost and service life to ensure that the equipment can achieve a win-win cost-effectiveness in the long run.
When choosing the type of crushing equipment, factors such as material type, production requirements, budget constraints, site change frequency, and the cost and workload of infrastructure construction and demolition need to be considered.