Mobile Crushing Plant

Shanghe Mobile Crushing Plant

A mobile crushing plant is a portable system, typically wheeled or tracked, which consolidates the core functions of material processing—feeding, crushing, screening, and conveying—into a single, movable entity. The principal benefit of this design is its ability to be relocated directly to the work site. This mobility substantially lowers costs associated with transporting raw materials and offers greater operational flexibility and efficiency than stationary crushing installations.

Core Industrial Applications

• Infrastructure Construction: Mobile plants are deployed directly on large-scale projects—such as highways, railways, and bridges—to produce aggregates on-site. This eliminates long-distance hauling, ensures a steady supply of base and surfacing materials precisely where needed, and significantly cuts transportation costs and emissions.
• Recycling & Urban Mining: These units are fundamental to the circular economy, processing construction and demolition (C&D) waste—concrete, asphalt, brick—directly at demolition sites or recycling yards. They transform waste into high-quality recycled aggregates, diverting material from landfills and supplying sustainable raw materials for new construction.
• Mining & Quarrying: In open-pit mines and quarries, mobile crushers follow the working face, performing primary crushing where the material is extracted. This “pit-to-portable” approach drastically reduces the need for dump trucks to haul raw ore over long distances, optimizing fuel use and increasing overall operational efficiency.

Advantages

Financial & Logistical Efficiency

• Direct Cost Reduction: Processing material directly at the source eliminates or drastically reduces hauling costs, which can constitute up to 30% of total project expenses. Mobile plants can lower these transport costs by an estimated 20–30%.
• Lower Capital Outlay: They require minimal permanent infrastructure—no deep concrete foundations or extensive fixed utilities—significantly reducing upfront site preparation investment.
• High Resale Value: Their cross-industry versatility (aggregates, mining, recycling) contributes to stronger residual values and a favorable long-term return on investment.

Operational Agility & Speed

• Rapid Deployment: Mobile plants offer a “plug-and-play” solution, often becoming fully operational within 4 to 6 hours of site arrival, bypassing the weeks of civil work required for stationary installations.
• Project Flexibility: Their mobility allows contractors to follow a resource (e.g., an advancing quarry face) or seamlessly relocate between job sites, making remote or short-duration projects economically feasible.

Environmental & Technological Leadership

• Reduced Environmental Impact: On-site processing slashes truck traffic, fuel consumption, and associated carbon emissions. Modern systems integrate advanced dust suppression and noise control for cleaner, compliant operation.
• Integrated Intelligence: 2026 models feature sophisticated telematics and automation, enabling real-time performance monitoring, remote diagnostics, and automated adjustments, often allowing single-operator control of the entire crushing circuit.

Types

Classification by Chassis Type

This defines the plant’s mobility and terrain capability.

Classification by Crushing Technology

The core crusher unit defines the plant’s material processing capability and product shape.

• Mobile Jaw Crushers: The primary crushing workhorse. Use compressive force to break down large, hard feed materials (e.g., granite, basalt) into coarse aggregate.
• Mobile Impact Crushers: Ideal for secondary crushing and recycling. Utilize high-speed impact to produce well-shaped, cubicle aggregate from softer materials like limestone and recycled concrete or asphalt.
• Mobile Cone Crushers: Designed for secondary and tertiary crushing of hard, abrasive stones. Use a gyrating mantle to produce consistent, high-quality aggregate for precision applications like concrete and asphalt mixes.
• Mobile Hammer Crushers: Employ impact from swinging hammers to crush brittle materials (e.g., limestone, coal) in smaller-scale mining or aggregate production.
• Mobile Screening Stations: Dedicated units for sizing and sorting. Often used in conjunction with crushing plants in a closed circuit to separate finished product and recirculate oversized material.

Classification by Power System

Power source selection balances operational flexibility, efficiency, and environmental compliance.

• Full Hydraulic Drive: Common on tracked units, using a diesel engine to power hydraulic motors for crusher and track movement. Offers robust power and high maneuverability.
• Hybrid Drive (D-type): Combines a diesel engine with electric crusher motors. Provides significant fuel savings, lower emissions, and reduced noise levels during operation.
• Electric Drive (E-type): Can be connected to an external grid or onboard generator. Enables zero-exhaust operation at the point of use, offering the lowest operating costs and emissions for fixed-site or urban projects.

Working Principle

The plant functions as a continuous production line through the following stages:

1. Feeding
   Material is loaded into a vibrating feeder, which regulates a consistent flow to the crusher. A grizzly section often pre-screens out fine material, directing it away from the crusher to improve efficiency and reduce wear.
2. Crushing
   The heart of the plant, where size reduction occurs. The crushing action varies by machine type:
   • Compression (Jaw & Cone Crushers): Material is squeezed between two surfaces until it fractures.
   • Impact (Impact & Hammer Crushers): Material is shattered by rapid blows from hammers or blow bars.
3. Screening
   Crushed material is sent to a vibrating screen, which sorts it into different product sizes based on mesh openings. Properly sized material proceeds to stockpile conveyors.
4. Conveying & Stockpiling
   A system of conveyor belts transports the screened products to separate stockpiles based on size.
5. Recirculation (Closed-Circuit Systems)
   Oversized material from the screen is automatically fed back to the crusher via a return conveyor for further processing, ensuring precise control over the final product size.

Key Components & Features

• Mobility System: Tracked for off-road stability and self-propulsion on difficult terrain; Wheeled for easy highway towing between sites.
• Power Source: Options include diesel engines, direct electric drive (for fixed-site operation), or hybrid systems balancing power and fuel efficiency.
• Automation & Control: Modern plants use PLC systems and telematics for remote monitoring, automated operation, and real-time tracking of performance and maintenance data.

Crusher Types: Principle & Application

Specification