Как выбрать между мобильной дробильной станцией и стационарной дробильной производственной линией?

Comparison of Fixed and Mobile Crushing Production Lines: Advantages, Costs, and Selection Criteria

In the mining industry, fixed crushing production lines are favored for their long service life, mature technology, and stability, making them the predominant choice for most mining operations. However, with advancements in mining equipment and process technology, cost-effective mobile crushing stations have gained significant popularity. This article compares the advantages, investment costs, and selection considerations for fixed and mobile crushing lines, using a case study of a mine processing 4,000 tons of raw ore per day, employing a two-stage, one-closed-circuit crushing process to reduce ore from a maximum size of 600 mm to below 30 mm.

1. Comparison of Fixed and Mobile Crushing Stations

1.1 Fixed Crushing Station

A fixed crushing station involves installing crushing equipment at a designated site, where it remains permanently after installation.

Fixed stations require significant civil engineering, including equipment foundations, partial flooring, retaining walls, concrete silos, steel-framed workshops, and conveyor corridors, leading to substantial construction costs.

Advantages:

1. Mature Process: Conventional layout with well-established construction and operational practices.
2. Large-Scale Equipment: Allows for centralized crushing with larger equipment models.

Disadvantages:

1. Large Footprint: Requires significant space, with strict site selection criteria.
2. High Civil Costs: Large-scale construction with long lead times and multiple uncontrollable factors.
3. Labor-Intensive: Requires 5 operators per shift and 2 loaders.
4. Complex Process: Involves lengthy workflows, multiple equipment units, and challenging management.
5. High Crushing Costs: Requires short-haul ore transport, increasing operational expenses.
6. Non-Reusable Infrastructure: Civil works become obsolete once the mine is depleted.

1.2 Mobile Crushing Station

Mobile crushing stations offer mobility and flexibility, allowing direct use on mining platforms. They require no workshops or civil foundations, making them ideal for mines with land acquisition challenges. After mine depletion, mobile stations can be relocated to other sites, enhancing their economic value.

Advantages:

1. Pre-Assembled Equipment: Factory-manufactured, requiring no on-site installation; operational upon power connection.
2. Small Footprint: Can operate on existing mining platforms.
3. Streamlined Process: Excavators feed blasted ore directly into the equipment hopper, and processed ore is transported to the stockyard by trucks.
4. No Civil Works: Eliminates the need for workshops or foundations.
5. Flexible Power Options: Supports oil-electric hybrid modes, enabling operation in remote areas with self-propelled or remote-controlled mobility.
6. Lower Investment: Reduced upfront costs compared to fixed stations.
7. Minimal Labor: Requires only 2 operators per shift, with 1 excavator for feeding and 1 loader for material handling.
8. Versatile Reuse: Can be relocated to other sites for crushing raw ore, construction aggregates, demolition waste, or materials for highways and railways.
9. Lower Crushing Costs: Eliminates short-haul transport, reducing operational expenses.
10. Quick Deployment: Short manufacturing cycles and fast returns on investment.

Disadvantages:

1. Higher Costs for Large Capacities: Equipment for high-capacity processing can be expensive.
2. Multiple Units for Large Sites: Multiple mobile stations may be needed for mines with numerous extraction points.

2. Investment and Operating Cost Comparison

2.1 Investment Costs

• Fixed Crushing Station: Total investment, including equipment, workshops, and civil works, is approximately 10 million CNY.
• Mobile Crushing Station: A complete set, including a mobile jaw crusher, mobile cone crusher, and mobile screening machine, costs around 5 million CNY.

Savings: Mobile crushing stations save approximately 5 million CNY compared to fixed stations.

2.2 Operating Costs

1. Power Consumption:
   Both fixed and mobile stations have an installed capacity of 500 kW, resulting in similar electricity costs.
2. Labor:
   • Fixed stations require 5 operators per shift.
   • Mobile stations require 2 operators per shift, reducing labor costs.
3. Wear Parts: Costs for equipment wear parts are comparable for both systems.
4. Heavy Machinery:
   • Fixed stations require 2 loaders: one for feeding the ore silo and one for loading crushed ore.
   • Mobile stations require 1 excavator for feeding and 1 loader for loading crushed ore.
   • While mobile stations use an additional excavator, they require one fewer loader and 3 fewer operators per shift. Overall, operating costs are similar.

3. Case Study Analysis and Selection Considerations

For a mine processing 4,000 tons of raw ore daily, the investment and operating costs of fixed and mobile crushing stations are comparable. However, mobile crushing stations offer significant advantages:

• Mobility: Can be deployed directly on mining platforms, offering flexibility and convenience.
• No Civil Works: Eliminates the need for costly workshops and foundations, ideal for mines with land constraints.
• Reusability: Can be relocated to other sites after mine depletion, enhancing economic viability.

Selection Criteria:
Choosing between a fixed or mobile crushing line requires a comprehensive analysis of multiple factors, including:

• Site Conditions: Mobile stations are better suited for sites with limited space or land acquisition challenges.
• Project Duration: Fixed stations may be preferable for long-term, large-scale operations, while mobile stations excel in shorter-term or multi-site projects.
• Budget Constraints: Mobile stations offer lower upfront costs and faster deployment.
• Operational Flexibility: Mobile stations provide greater adaptability for dynamic mining environments.

In conclusion, while both options have their merits, mobile crushing stations are often more economical and practical, particularly for mines requiring flexibility, rapid deployment, and reusability. A thorough evaluation of site-specific needs and operational goals will guide the optimal choice.China Crusher ManufacturerApplications and Advantages of Mobile CrushersAdvantages of Crawler Type Mobile Impact Crusher Produced in China