What is a crushing plant?

“Crushing plant” is an industrial term, also called a crusher or crushing plant. Crushing machine plants are equipment or facilities used to crush large materials (such as rocks, ores, coal, limestone, etc.) into smaller particles. Crushing stations crush large materials into smaller particles by extrusion, shearing, impact, grinding, etc., and can be widely used in mining, metallurgy, building materials, roads, railways, water conservancy and chemical industries. It is an important equipment for processing materials such as ores, rocks, construction waste, and scrap metals.

Definition and use

Crushers are usually used to process various materials such as waste, construction waste, and ore. They are important equipment in sand and gravel production lines, mineral processing production lines, pharmaceuticals, chemicals, food, magnetic materials, powders and other industries. Through crushing, large pieces of material can be converted into small pieces or powders of the required particle size to meet the requirements of different industries for material particle size.

Crusher equivalent name

Mining crushing plant

Crushing station is used in mining: Crushing station is the most critical mechanical equipment in mining. Open-pit mining production is inseparable from crushing equipment. The use of suitable crushing station can effectively reduce the particle size of ore rock transportation and improve production efficiency.

Metal ore is generally used for mineral processing, but it needs to be processed by a crusher before mineral processing to improve the mineral processing grade. At present, the use of suitable crushing station has become a trend for metal open-pit mines to improve production efficiency. The application of crushing station can significantly improve the mineral processing grade of ore and reduce transportation costs.

Types of mining crushing plants

What are the types of mining crushers? Open-pit mining crushing stations can be divided into crushers of various structures according to the different crushing equipment, the degree of fixation of the foundation and the application scenarios, such as common mobile, fixed, Jaw crusher, etc.

10 types of mining crushers

Mining crushing plants Type	Product Features	Product Display
Mobile Crusher Plant	Mobile crusher plant (also called mobile crusher unit) is a mobile crushing equipment that integrates feeding, crushing, screening, conveying and other functions. Mobile crushing plant is widely used in mining, construction, highway, railway, water conservancy and other fields, and is suitable for crushing and processing materials such as ores, rocks, construction waste and other materials of various hardness. Smat mobile crusher plant adopts tire-type or crawler-type walking device, which is convenient for rapid transfer between different work sites, reduces material transportation costs, has strong adaptability, and is highly efficient and energy-saving.
Semi-mobile Crushing Plant	Semi-mobile crushing plant is a kind of equipment between fixed crushing station and fully mobile crushing station, which is widely used in open-pit mining operations. Semi-mobile crushing plant is a kind of semi-mobile crushing equipment, which is usually installed on a suitable working plane of an open-pit mine. As the mining step advances, it is moved as a whole or in parts by traction equipment (such as crawler transporter). It combines the high processing capacity of fixed crushing station and the flexibility of mobile crushing station, adopts advanced crushing technology and high-quality crushing equipment to improve the crushing ratio and production efficiency. At the same time, each component adopts modular design, which is convenient for quick replacement and maintenance.
Stationary crushing plant	A stationary crushing station is a permanently installed crushing facility, usually located outside the boundary of an open-pit mine or inside a stope, and has a solid connection to the ground. It is fixed in position throughout the service life of the mine, which is the same as the service life of the mine. The fixed crushing station is installed on a concrete foundation, with a solid structure and stable operation. It is suitable for long-term, large-scale production and can maintain stability and reliability for a long time. Its design is mature, the technology is reliable, and it can handle large pieces of ore. It is usually equipped with a gyratory or jaw crusher.
Semi-fixed Crushing Plant	Semi-fixed crushing plant is a transitional form between semi-mobile crushing plant and fixed crushing plant. Semi-fixed crushing plant is connected to the ground through a solid foundation and is usually installed on a fixed slope of the mine to reduce the frequency of relocation and extend its service life. Anchor piles (in bedrock) or reinforced concrete foundation (in loose areas) are usually used. This design enables it to withstand the weight of large equipment and long-term operation stability.
Jaw Crusher Plant	Jaw crusher machine is a kind of equipment that uses two jaws (movable jaw and fixed jaw) to make periodic relative motion to achieve material crushing. Jaw crusher machine is one of the most common crushing equipment, widely used in mining, metallurgy, building materials, chemical industry and other fields, mainly used for coarse and medium crushing of ores and rocks of various hardness. Jaw crusher is based on extrusion crushing. The movable jaw plate periodically approaches and leaves the fixed jaw plate through the rotation of the eccentric shaft. When the movable jaw approaches the fixed jaw, the material is squeezed and crushed; when the movable jaw leaves the fixed jaw, the crushed material is discharged from the crushing chamber by gravity. This periodic extrusion and release process achieves the crushing of materials.
Cone Crusher Machine	Cone crusher is a kind of crushing equipment widely used in industries such as mining, metallurgy, construction and sand and gravel yards. It is mainly used for medium and fine crushing of ores or rocks of various hardness. Cone crusher applies compression force to the material through a rotating conical crushing head (moving cone), thereby achieving material crushing. Its core components include a moving cone driven by an eccentric shaft and a fixed fixed cone. When the motor drives the eccentric shaft to rotate, the moving cone performs a pendulum motion around the center line, and the material is squeezed, sheared and bent in the crushing chamber between the moving cone and the fixed cone, and finally crushed into smaller particles. This crushing method not only improves energy utilization efficiency, but also produces products with more uniform particle size.
Impact Crusher Machine	An impact crusher is a device that uses impact force to break materials. It breaks materials into smaller particles through the interaction between a high-speed rotating rotor and an impact plate (or impact plate). This type of crusher is widely used in construction, demolition, recycling and mining, and can handle a variety of materials such as concrete, asphalt, and natural rock. The core component of an impact crusher is a high-speed rotating rotor with a hammer or impact plate mounted on it. After the material enters the crushing chamber, it is hit by the high-speed rotating hammer and then collides with the impact plate or impact plate to further break it. This process is repeated many times until the material reaches the desired particle size and is discharged from the crusher.
Hammer Crusher	Hammer crusher is a kind of equipment that uses high-speed rotating hammers to impact and crush materials. It is widely used in cement, chemical, electric power, metallurgy and other industries, mainly used for crushing medium hardness and brittle materials. The core component of the hammer crusher is a high-speed rotating rotor with multiple hammers installed on it. After the material enters the crushing chamber, it is hit by the high-speed rotating hammers, and then collides with the crushing plate or screen bars for further crushing. The crushed material is discharged through the screen bars, and the material that does not meet the particle size requirements continues to be crushed. The crushing ratio of the hammer crusher can usually reach 10-25, or even higher, and it can crush large pieces of material into smaller particle sizes at one time.
Combination Crusher	Combination crusher is a high-efficiency crushing equipment that combines multiple crushing principles. It is widely used in mining, metallurgy, building materials, chemical industry and other industries. It can handle materials with medium hardness and below, such as ore, limestone, coal gangue, shale, etc. The material falls vertically from the top of the crusher into the high-speed rotating impeller. Under the action of high-speed centrifugal force, the material collides and squeezes with the material around the impeller at high speed, and is further crushed. The crushed material continues to be ground and crushed in the vortex between the impeller and the casing, and is finally discharged from the bottom. Combination crusher can achieve efficient crushing of large pieces of material, and the crushing ratio can reach 10-25.
Two-stage Crusher	The two-stage crusher is a high-efficiency crushing equipment. It adopts a dual-rotor design, integrates the coarse crushing and fine crushing functions, and can perform two-stage continuous crushing of materials. The two-stage crusher is particularly suitable for processing high-humidity materials, such as coal gangue, shale, slag, construction waste, etc., and can effectively avoid the blockage problem caused by high humidity of traditional crushers. The two-stage crusher consists of two sets of upper and lower rotors. The material is first crushed by the upper rotor and then further crushed by the lower rotor. This design achieves the dual effects of “hammering materials” and “material beating materials”, and the particle size of the crushed materials is more uniform.

Crushing machine working principle

The working principle of the crusher mainly depends on its crushing method, which includes but is not limited to extrusion, splitting, breaking, shearing, impact or striking. In actual applications, crushers often use a combination of multiple crushing methods to achieve the best crushing effect. For example:

Extrusion crushing: The working surface of the crushing machine applies pressure to the material sandwiched between it, and the material is crushed when the compressive stress on the material reaches its compressive strength limit.
Splitting shear crushing: The edges of the crushing working surface wedge into the material, causing tensile stress inside the material. When the value exceeds the tensile strength limit of the material, the material splits and produces powder at the contact point.

Crushing machine advantages of using in mining

The application of crushers in mining has many advantages, which not only improves the production efficiency of mines, but also reduces operating costs, and also plays a positive role in environmental protection and resource utilization.

Efficient crushing capacity: Crusher can quickly crush large pieces of ore into smaller particles to meet the needs of subsequent processing. For example, jaw crusher can efficiently handle ores of various hardness by simulating the movement principle of animal jaws, especially suitable for primary crushing in mining.

Multi-stage crushing design: Equipment such as double-stage crusher and cone crusher adopt multi-stage crushing method, which can realize integrated processing from coarse crushing to fine crushing, and significantly improve crushing efficiency.

Wide applicability: Crusher can adapt to ores of various hardness and particle size. For example, cone crusher can handle ores of different particle size and hardness by optimizing the crushing chamber design to meet diversified production needs.

Flexible adjustment: The discharge particle size of equipment such as jaw crusher and impact crusher can be adjusted, and the crushing particle size can be flexibly set according to the specific needs of the mine.

Simple structure and convenient maintenance: Equipment such as jaw crushers and impact crushers have simple structures, easy replacement of wearing parts, and low maintenance costs.

Strong durability: Modern crushers use wear-resistant materials and optimized designs to extend the service life of equipment, reduce downtime and maintenance costs.

Low noise and dust emissions: Impact crushers have low noise and less dust during the crushing process, which meets environmental protection requirements.

Resource recovery and reuse: Jaw crushers can be used to process mine waste and tailings to maximize resource utilization and reduce environmental impact.

Intelligent control: The crushers produced by Smat Machine are equipped with advanced control systems that can monitor the operating status of the equipment in real time, automatically adjust the crushing parameters, and realize intelligent operation and maintenance warnings.

“More crushing and less grinding” process: Equipment such as cone crushers and two-stage crushers can achieve the process requirements of “more crushing and less grinding”, reduce grinding pressure, and improve mineral processing efficiency.

Energy saving and consumption reduction: By optimizing the crushing process and equipment design, crushers can reduce energy consumption, which is in line with the development trend of green mines.

Combination of fixed and mobile: Mines can choose fixed crushing stations or mobile crushing stations according to their needs. Mobile crushing stations are particularly suitable for mining areas with complex terrain and large changes in the working environment, and can be put into use quickly.

Customized design: Smat machine crushers can be customized according to the specific needs of mines to meet different production scales and process requirements.