A mobile crusher is a portable crushing and screening machine designed to crush large and hard materials such as stone, rock, concrete, and asphalt into smaller pieces. These machines are mounted on wheeled or tracked chassis and are easily transportable between sites. Compared to stationary systems, mobile crushers are more flexible and offer quick setup, making them ideal for temporary projects and remote job sites.

What is the Purpose of a Mobile Crusher?

Mobile crushers are primarily used on construction sites, especially where demolition debris, natural stone, or other bulk materials need to be crushed and reused directly on site. These machines reduce the need for transportation, accelerate the work schedule, and offer significant cost savings. Mobile crushers contribute to sustainable construction practices by enabling on-site material recycling and minimizing environmental impact.

How Does a Mobile Crusher Work?

The working principle of a mobile crusher depends on its type (jaw, impact, or cone crusher), but the general process includes the following steps:

  1. Material is fed into the feed hopper using a loader or excavator.

  2. The vibrating feeder transports the material to the primary crusher unit.

  3. The material is crushed into smaller pieces by the crusher (jaw, impact, or cone).

  4. Crushed material passes through a screening system, where it is separated into different sizes.

  5. Desired sizes are conveyed to the stockpile via conveyor belts.

  6. Oversized material is redirected to the crusher for additional reduction.

Mobile crushers can be powered by diesel engines or connected to the electrical grid. They are often equipped with automation systems for remote monitoring and control.

In Which Areas Are Mobile Crushers Used?

  • On-site crushing and recycling in construction projects

  • Highway and railway construction

  • Dam, bridge, and tunnel construction

  • Temporary quarry operations

  • Concrete and asphalt recycling plants

  • Urban demolition and redevelopment projects

What is a Stationary Crusher?

A stationary crusher is a fixed crushing and screening system designed for long-term use at a specific site. It is used to process raw materials such as stone, rock, and ore into aggregates and other construction materials. Stationary crushers are typically installed in quarries or mining sites and are built for high-capacity continuous operation.

What is the Purpose of a Stationary Crusher?

Stationary crushers are used where large volumes of material need to be processed continuously. They transform raw materials into usable aggregates like gravel, crushed stone, sand, and various fractions required for concrete, asphalt, and other industrial uses. These systems are designed for durability, efficiency, and cost-effectiveness in large-scale industrial applications.

How Does a Stationary Crusher Work?

The process is more complex than mobile crushers due to higher capacities and permanent installations:

  1. Material is delivered to the feed area by truck or excavator.

  2. The primary crusher (usually a jaw crusher) breaks the material into smaller pieces.

  3. The crushed material is transported by conveyor belts to secondary crushers (cone or impact crushers).

  4. Screening systems classify the material into specific sizes.

  5. Finished materials are transferred to storage areas or stockpiles.

  6. The entire system is automated and monitored for consistent production.

In Which Areas Are Stationary Crushers Used?

  • Quarries and natural stone processing plants

  • Aggregate production facilities

  • Cement, asphalt, and concrete batching plants

  • Infrastructure megaprojects (dams, highways, harbors)

  • Mining and metallurgy industries

Differences Between Mobile and Stationary Crushers

  1. Installation and Mobility:
    Mobile crushers can be easily relocated between sites, whereas stationary crushers are fixed in one location.

  2. Setup Time:
    Mobile units can be deployed within hours or days, while stationary plants require several weeks for installation and commissioning.

  3. Capacity and Performance:
    Stationary crushers are designed for higher throughput and can handle larger feed sizes. Mobile crushers offer flexibility at the cost of lower capacity.

  4. Investment and Operating Costs:
    Stationary systems typically require a higher initial investment but offer lower long-term costs. Mobile systems are more cost-effective for short-term projects.

  5. Flexibility and Use Cases:
    Mobile crushers can serve multiple job sites and changing conditions. Stationary crushers are suited for permanent production facilities.