In industries such as mining, sand and gravel aggregate production, and construction waste treatment, crushers are one of the core equipment. Choosing a suitable mining crusher can not only improve production efficiency and reduce energy consumption, but also extend equipment life and reduce maintenance costs. However, there are many types of crushers on the market, such as jaw crushers, cone crushers, impact crushers, hammer crushers, etc. How to choose the most suitable equipment according to actual needs?
This article will introduce in detail the 5 key factors for selecting mining crushers, compare the advantages and disadvantages of different crushers, and provide a selection parameter table and cost analysis to help you lock in the best equipment within 10 minutes!
Five key factors for selecting a mining crusher
1. Material properties (hardness, humidity, particle size)
Hardness (Mohs hardness):
• High-hardness ore (such as granite, basalt) → jaw crusher or cone crusher
• Medium-low hardness ore (such as limestone, coal gangue) → impact crusher or hammer crusher
• Humidity: Too high humidity can easily lead to blockage, so you need to choose a model with a grate screen (such as a hammer crusher)
• Feed particle size: Large pieces of ore (>500mm) need to be crushed by jaw crusher before entering secondary crushing
2. Capacity requirements (tons/hour)
Comparison of processing capacity of different crushers:
| Crusher type | Typical capacity (t/h) | Applicable scenarios |
| Jaw crusher | 50-1500 | Coarse crushing (primary crushing) |
| Cone crusher | 50-1000 | Medium and fine crushing (high hardness materials) |
| Impact crusher | 50-500 | Medium and fine crushing (medium and low hardness materials) |
| Hammer crusher | 100-3000 | Soft material crushing (such as coal gangue) |
Selection suggestions:
• Small sand and gravel plant (<100t/h) → jaw crusher + impact crusher combination
• Large mine (>500t/h) → jaw crusher + cone crusher multi-stage crushing
3. Discharge particle size requirements
• Coarse aggregate (such as roadbed gravel) → jaw crusher/cone crusher (discharge 30-100mm)
• Fine aggregate (such as machine-made sand) → impact crusher/impact crusher (discharge 0-5mm)
• High-precision shaping → vertical shaft impact crusher (sand making machine)
4. Energy consumption and operating costs
• Cone crusher: high energy consumption, but long life of wear parts (suitable for long-term high-load operation)
• Impact crusher: low energy consumption, but fast hammer wear (suitable for small and medium-sized production)
• Jaw crusher: simple maintenance, but lower efficiency than cone crusher
Cost comparison (taking the treatment of 100t/h granite as an example):
| Equipment combination | Power consumption (kW·h/t) | Wear parts cost (yuan/ton) |
| Jaw crusher + cone crusher | 1.8-2.2 | 0.5-1.0 |
| Jaw crusher + impact crusher | 1.5-1.8 | 1.0-1.5 |
5. Environmental protection and intelligent requirements
• Dust control: choose a closed production line with a pulse dust collector
• Noise control: The impact crusher is noisy, and the cone crusher is quieter
• Intelligent monitoring: Modern crushers can be equipped with IoT sensors (real-time monitoring of bearing temperature, vibration, etc.)
Comparison and selection recommendations of mainstream mining crushers
1. Jaw crusher
✔ Advantages: simple structure, easy maintenance, suitable for coarse crushing of large pieces of materials
✘ Disadvantages: uneven product particle size, high energy consumption
Applicable scenarios: primary crushing of hard rocks such as granite and basalt
2. Cone crusher
✔ Advantages: large crushing ratio, good product particle shape, long life of wear-resistant parts
✘ Disadvantages: high equipment price and complex maintenance
Applicable scenarios: medium and fine crushing of high-hardness ores (such as iron ore and copper ore)
3. Impact crusher
✔ Advantages: excellent output particle shape and low energy consumption
✘ Disadvantages: fast wear of plate hammer, not suitable for high-hardness materials
Applicable scenarios: secondary crushing of limestone and construction waste
4. Hammer crusher
✔ Advantages: one-time molding, high production capacity
✘ Disadvantages: The grate bars are easy to clog, not suitable for wet materials
Applicable scenarios: Medium and low hardness materials such as coal gangue and shale
Mining crusher selection flow chart
1. Determine material characteristics (hardness, moisture, particle size) → 2. Calculate capacity requirements → 3. Select crushing stage (coarse crushing/medium crushing/fine crushing) → 4. Compare equipment energy consumption and cost → 5. Consider environmental protection and intelligent needs
FAQs
Q1: Which one is better for crushing granite, the jaw crusher or the cone crusher?
→ The jaw crusher is used for coarse crushing, and the cone crusher is used for medium and fine crushing, and they are usually used in combination.
Q2: Which crusher is the most cost-effective for a small sand and gravel plant?
→ The combination of the jaw crusher and the impact crusher is recommended, with low investment and simple maintenance.
Q3: How to reduce the energy consumption of the crusher?
→ Optimize the crushing ratio, regularly maintain the bearings, and select a variable frequency motor.
Choosing a suitable mining crusher requires comprehensive consideration of material characteristics, production capacity, discharge requirements, cost and environmental factors. The parameter comparison table and selection logic provided in this article can help you make a quick decision.
For further consultation on equipment models and quotations, please contact our technical team!
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