Mining and Quarrying
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The mining industry’s crushing and grinding requirements have changed dramatically over the last 20 years. With a focus on lowering costs, and increasing production and energy efficiency, industries require substantial crushing equipment.
Modern cone crushers that use hydraulic hold-down clamping allow industries to crush more capacity, with much more power than ever before. The automatic control of Cone Crushers has maximised power draw and through put exponentially.
Cone crushers dominate the hard rock crushing market as they are suited to secondary, tertiary and quaternary applications.
The Cone Crusher provides an excellent reduction and product cubicity for the production of high quality aggregate and sub-base materials. Uncrushable materials will not affect the functionality of the crusher due to its hydraulic release capabilities, which removes the material from the chamber safely.
With a re-circulating conveyor and double desk screen, the Powerscreen range of cone crushers provide the complete crushing and screening process in a single chassis design.
Three end products are available, when oversized material doesn’t require re-circulation to the crusher. These multiple applications within a single machine provides the diversity the mining and quarrying industries require.
Recycling
Where old asphalt was traditionally seen as useless due to its two main materials – bitumen and aggregates – modern day crushers can separate bitumen and aggregates for reuse as new asphalt.
Modern Asphalt stations can create new asphalt mix with 70% recycled materials. This has made huge strides from the past where asphalt was rarely recycled because it had to be done through melting. This required huge amounts of energy and was highly unsustainable.
The mobile nature of the Powerscreen Cone Crusher range means materials can be crushed close to the material location, saving huge amounts on transport costs.
Mining, quarrying and recycling plants make use of the Powerscreen range of Cone crushers thanks to their industry leading applications and heard wearing structures.
In recent years, SBM has introduced two new models of mobile crushers, the NK Portable Crusher Plant and MK Semi-mobile Crusher and Screen. Since their launch, they have gained popularity among customers worldwide. By 2023, we have achieved numerous successful cases of mobile crusher production lines in countries such as Malaysia, Congo, Guinea, the Philippines, Russia, Nigeria, Indonesia, Saudi Arabia, Ethiopia, and Cameroon.
According to feedback from our customers, the use of mobile crushers has significantly improved the production efficiency of quarries. These new devices, through on-site mobile crushing, have greatly reduced the time required for material loading and transportation. Simultaneously, they incorporate advanced safety designs, effectively enhancing the working security for operators. Many customers have expressed that the new mobile crushers have brought significant economic benefits to their businesses, thanks to the improved efficiency and reduced safety costs.
This article explores how mobile crusher has transformed quarry operations by enhancing efficiency and providing a safer working environment for operators.
Traditional stationary crushers tie production to a single location near ore sources. Hauling distances inflate costs as equipment toils transporting material. Mobile crushers circumvent this by relocating to extraction zones, shortening loading cycles.
Closer positioning cuts loading/unloading times up to 70%. Mobility also alleviates issues from depleted seams by enabling crusher redeployment once areas are exhausted. This sustains throughput.
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Studies show mobile units increase utilization by 20-30% versus stationary equivalents. Continual repositioning exploits all reserves, maximizing yields. Fewer wasted man-hours are invested in non-productive hauls.
Time savings translate directly to heightened throughput and annual output. With shorter cycles, identical capacity crushers can process 30-40% more volume annually. For major producers, mobility easily adds millions in revenue.
Although upfront mobile crusher acquisition entails greater outlay than renting stationary variants, lower lifetime expenses more than offset initial premiums.
Primary savings stem from reduced haulage requirements. Shortening transportation distances cuts fuel burn and maintenance for loaders, trucks. One study found a 20% cut in associated owning and operating expenses.
Fewer equipment hours also prolong component life, slashing periodic overhauls. Without constant loading/unloading vibrations, crushers endure less wear. Maintenance intervals extend.
By eliminating loading/dumping fees at fixed plants and tailings disposal costs, other overhead is trimmed. These cumulative reductions deliver 2-4 year payback periods.
Perhaps most critically, mobility rescues workers from hazardous fixed plant interfaces. Stationary crushing involves unsafe truck/machine interactions, with restricted sightlines exacerbating risks.
Mobile units reduce interaction points by 70-90%. Operators need only feed machines from ramps, not navigate congested plant roadways. Accident rates at mines adopting mobility have plunged 25-50%.
Fewer pieces of equipment on site also lessens dust/noise pollution exposures. Mobile units consolidate functions of loaders, haul trucks and ancillary plant into one package. Workers stay safer distances from sources.
Transportability liberates personnel from confined plant terrain. Exploitation can shift to remote pits with limited infrastructure, precluding development of new fixed facilities. Workers are spared associated construction dangers.
Latest innovations further heighten operator safety and efficiency. Advanced hydraulic tracking and auto-lubrication systems automate machine movements andmaintenance, eliminating hazards.
Hybrid-electric drives minimize refueling needs. On-board analytical tools continuously monitor component condition, flagging issues early to avoid breakdowns. Remote diagnostics support reduces on-site servicing.
Fleet management software plots optimum routes between pits using real-time GPS tracking. This eliminates deadhead repositioning time. AI-assisted auto-targeting uses computer vision to guide feeding for maximum throughput.
Looking ahead, 5G connectivity and automation promise greater versatility as pilotless units are remotely controlled. This will distance staff further from operational perils.
Mobile crushers have become an indispensable asset in the quarrying industry, significantly improving efficiency and operator safety. Their ability to process materials on-site, increased production capacity, and versatility in crushing operations contribute to enhanced productivity and reduced operational costs. Moreover, the incorporation of remote operation capabilities, advanced control systems, ergonomic designs, and dust suppression systems prioritizes the safety and well-being of operators.
As the quarrying industry continues to evolve, mobile crushers will remain at the forefront of innovation, facilitating safer and more efficient operations. Their positive impact on quarry efficiency and operator safety make them an essential tool for modern quarrying practices.
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