A crusher is an integrated system of crushing and screening machines that break down hard materials such as stone, rock, concrete, and ores into smaller, usable sizes. Typically composed of a feeder, crusher (jaw, impact, cone, etc.), screening unit, conveyor belts, and a control system, crushers are widely used in stone quarries, concrete and asphalt recycling plants, and mining operations.

A crusher processes bulk material into standardized aggregate sizes for construction applications including road bases, concrete mixes, asphalt, dam fills, and railway ballast. It also enables recycling by crushing demolition debris into reusable materials.

The process begins by feeding raw material into the feeder. The primary crusher (usually a jaw crusher) performs an initial coarse crush. For finer gradation, secondary crushers (cone or other types) are used. Screen units separate the material by size, and conveyor belts transport it to storage or packaging areas.

What is a mobile crusher, what is it used for, how does it work, and where is it used? (written explanation)

A mobile crusher is a crushing and screening plant mounted on a wheeled or tracked chassis, enabling transportability and on-site crushing operations. It can be mobilized to different locations and become operational within hours.

Mobile crushers are ideal for temporary projects or recycling sites where fixed plants are impractical. They reduce transportation costs, save time, and minimize environmental disturbance by crushing material at the source.

Powered by generators or electric motors, a mobile crusher includes an integrated feeder, crusher (jaw, cone, or impact), screening unit, and conveying system. The entire line functions in sequence for feeding, crushing, screening, and transporting.

Mobile crushers are commonly used in road, bridge, and tunnel construction, urban redevelopment, concrete/asphalt recycling, temporary mining operations, and mountainous or remote areas.

What is a stationary crusher, what is it used for, how does it work, and where is it used? (written explanation)

A stationary crusher is a fixed, high-capacity crushing and screening plant built on a concrete foundation for long-term continuous production. These plants are typically situated in mines, quarries, or cement plant raw material prep units.

Designed for heavy-duty use with high throughput, a stationary crusher uses multiple crusher types (jaw, cone, impact) and screening units, often controlled via automation systems.

Material is loaded into the feeder, passed through the primary crusher for coarse reduction, then through secondary crushers for fine sizing. Screens grade the material, and conveyor belts transfer it to stockpiles or feed lines.

Stationary crushers are used in permanent quarries, mining operations, cement plants, concrete aggregate centers, industrial mineral processing, and large infrastructure projects.

Differences between stationary and mobile crushers (written explanation)

Mobility: Mobile units can be driven between sites; stationary units remain at fixed installation.
Installation time: Mobile plants can be set up in hours; stationary plants require days or weeks.
Capacity: Stationary plants are fitted for high throughput; mobile units handle mid-range capacity.
Flexibility: Mobile units can quickly switch between job sites; stationary plants are optimized for long-term operation.
Investment cost: Mobile setups have lower initial cost; stationary plants require more upfront investment but yield long-term efficiency.
Ideal usage: Mobile crushers are suited for temporary, site-specific needs; stationary crushers are designed for continuous, large-volume production.

What is a secondary crusher, what is it used for, how does it work, and where is it used? (written explanation)

A secondary crusher is used to further reduce material already processed by a primary crusher. It typically includes cone crushers, vertical shaft impact crushers (VSI), or horizontal shaft impact crushers (HSI).

Secondary crushers are essential for producing precise aggregate gradations for asphalt, concrete, and stone production. In mining, they are used for crushing ore to sizes suitable for processing.

Material is fed from the primary crusher into the secondary crusher, where high pressure, impact, or collision forces further reduce it. Screening units then classify the output, and conveyor belts transport the material for subsequent steps or storage.

Secondary crushers are widely used in stone and aggregate production plants, asphalt and concrete plants, precision crushing operations, and ore beneficiation facilities.