Mobile crushers bring significant operational advantages due to their mobility and versatility. They can be easily transported using standard low flatbed trucks, quickly adapted to fit the specific site requirements, and operated with ease. This essentially streamlines logistics, cuts down on expenses, and enhances productivity in quarry operations.

1. Mobile Crushers

Mobile crushers are mounted on a self-propelled steel platform equipped with wheels, crawlers, or pneumatic pads for movement. The platform incorporates all necessary auxiliary equipment and subsystems for crusher operation. They operate independently on the mine floor. Placed at the working face, the crusher minimizes the need for truck or front-end loader transport, with planned moves occurring between one day and one week.

In many crushing stations, apron feeders are employed to lift ore into the primary crusher’s feed opening. This design allows the crusher station to operate at ground level and move without the use of self-propelled modular transporters (SPMTs). 

Installation of mobile crushing plants is advantageous under specific conditions;

  • A clear and undisturbed geological situation, 
  • Straight and long benches for shiftable face conveyor installation, 
  • Long-term mine planning for various conveyors.

The benefits of fully-mobile crushers include

  • Elimination of truck transport
  • Reduced personnel requirements
  • Avoidance of high truck maintenance costs
  • Decreased mine traffic
  • Overall improvement in mine safety. 

However, there are drawbacks, including increased total capital cost, higher maintenance expenses due to the addition of an apron feeder. They have higher cost of crusher spare and wear parts related to crusher wear from using the apron feeder. 

The nature of the feeder can cause ore to concentrate on specific areas within the crushing chamber, leading to premature localized wear of the concaves and mantles. Although the use of alloy steels has addressed this issue to some extent, the higher cost of alloy steel components compared to manganese steel remains a concern, and availability is limited.

2. Maintenance of Mobile Crushers

Mobile crushers, designed for sizing hard materials like rock, gravel, and slag, are susceptible to excessive wear in their parts. Inadequate maintenance may lead to significant damage. Since all the components of the mobile crushers are interconnected, a lack of harmony affects the entire production process. This may result in added expenses and downtime. There is a correlation between well-maintained equipment and increased uptime, production, and overall profitability. Managing maintenance allows better control over operating costs, enhances safety for employees, and fosters a positive work environment. The recommended maintenance strategy involves a structured plan with daily checks, proactive schedules, spare parts inventory, and comprehensive documentation for planning and historical records.

2.1 Feeders Maintenance

    • The feed system is the first area of wear on the machine. Controlling of the feed size is crucial for optimal performance. 
    • Maintenance is required for the grizzly fingers. It requires rebuilding and applying a hard face to ensure the proper sizing of the material being removed is maintained.
    • Ensuring the mesh is well-maintained is crucial to prevent the material from deviating beyond the specified requirements.
    • The machine must be level to prevent increased wear on various components. If the machine is unlevel, it may cause increased wear on all components from the feeder, to the screens, crushing chambers and conveyor belts.

2.2. Crushers Maintenance

    • Crusher is the primary component of the mobile crusher that is subject to wearing
    • Blow bars, hood liners, apron liners and apron tips are the major wearing parts. 
    • Daily visual inspection of the crusher is recommended, with wear depending on the application and crushed material.

2.3 Conveyors Maintenance

    • Conveyors transport the material and their parts like belting, skirt flashing, belt cleaners, and cleaner blades are subject to wearing.
    • Proper tracking of conveyors is essential for proper functioning.
    • Avoid build-up underneath the conveyor to prevent damage.
    • Be aware of the signs indicating the need for belt replacement, such as worn rubber, dug-out patches, torn pieces, and tracks on the belt.

2.4 Screens Maintenance

    • Screens are vital in the crushing and screening operation.
    • Wear in woven wire mesh can lead to larger openings and decreased strength.
    • Regular checks for worn and broken wires, damaged crimps, and proper mesh tension are essential.

2.5 Engines & Hydraulics Maintenance

    • Regular engine maintenance to prevent small issues from becoming larger problems.
    • Checking and maintaining fluid levels (oil, coolant, hydraulics) and cleaning debris near the engine and radiator.
    • Adhering to the manufacturer’s recommended maintenance schedule.

3. Conclusion

Conduct daily system inspections to ensure major wear parts are secured and lubricated. Focus on areas like liners, crusher anvils, and blow bars, adjusting as needed for peak performance. Emphasize on the bearings, crushing chamber, screen cloth, and conveyor components during daily inspections. Regular servicing, including greasing bearings, prolongs the lifespan of the crusher and enhances resale value.

Overall, the maintenance strategy recommended includes a structured plan incorporating daily checks, proactive maintenance schedules, spare parts inventory, and documentation forms for planning and historical records. Regular inspections and proper attention to wear parts contribute to increased uptime, production, and overall profitability.

Novelty Structures supplies various Turkish made mobile crushers with different capacities and features. Please get into contact with our experts for more info through info@noveltystructures.com

Knowledge Hub