A mobile crusher is a portable crushing and screening plant mounted on a crawler or wheeled chassis. It is designed to process rocks, ores, concrete, asphalt, and other solid materials into aggregates (sand, gravel, crushed stone) directly at the job site. Unlike stationary crushers, mobile crushers can be easily relocated, making them ideal for temporary projects or remote locations.

Key Components:

  • Crusher Unit: Jaw crusher, impact crusher, cone crusher, or other crushing mechanisms.

  • Screening Unit: Vibrating screens or mobile screening systems.

  • Feeder: A hopper or vibro feeder to regulate material flow into the crusher.

  • Conveyor Belts: Systems to transport crushed materials.

  • Power Source: Diesel generator or external electricity connection.

  • Control Panel: Automation system for operator monitoring and control.

Purpose

  1. Size Reduction:

    • Breaks large rocks or construction waste into 0-50 mm aggregates.

    • Produces ready-to-use materials for concrete, asphalt, or road base layers.

  2. Waste Recycling:

    • Converts demolition debris (concrete, bricks) into reusable materials.

  3. Ore Preparation:

    • Reduces the size of extracted ores for easier transport or processing.

  4. Mobility and Flexibility:

    • Operates in confined spaces or temporary sites where fixed plants cannot be installed.

How Does It Work?

Mobile crushers operate in three main stages: crushing, screening, and transportation.

  1. Crushing Stage:

    • Primary Crushing: Raw material (e.g., a 500 mm rock) is fed into a jaw crusher via an excavator. The jaw crusher reduces it to 100-300 mm.

    • Secondary Crushing: Material from the primary crusher is further crushed by a cone crusher or impact crusher to 20-50 mm.

    • Tertiary Crushing (Optional): Additional crushers may be used to achieve finer particles (e.g., 0-10 mm).

  2. Screening Stage:

    • Crushed material passes through vibrating screens to classify it into sizes:

      • 0-5 mm: Fine sand or powder (for concrete production).

      • 5-15 mm: Gravel (for road sub-base).

      • 15-30 mm: Coarse gravel (for backfill).

  3. Transport and Storage:

    • Conveyor belts transfer sorted materials to stockpiles or trucks.

    • After completion, the plant can be relocated using its crawler tracks or trailer.

Applications

  1. Construction Industry:

    • Concrete and Asphalt Production: On-site aggregate supply for construction projects.

    • Road Building: Crushed stone for base and sub-base layers.

  2. Mining:

    • Ore Preparation: Reducing the size of gold, copper, or iron ores before transport.

  3. Recycling:

    • Demolition Waste: Reprocessing concrete and bricks from demolished structures.

    • Asphalt Recycling: Crushing old asphalt for reuse in new roads.

  4. Quarries:

    • Processing natural stones for decorative or structural purposes.

  5. Emergency Projects:

    • Disaster debris management (e.g., post-earthquake rubble recycling).

Advantages

  • Portability: Crawler or wheeled systems adapt to rough terrains.

  • Quick Setup: Operational within hours, unlike weeks for fixed plants.

  • Energy Efficiency: Modern units consume less fuel and reduce CO₂ emissions.

  • Versatility: Customizable with different crusher types (e.g., impact crushers for concrete, jaw crushers for hard rocks).