Quarry Crusher Equipment Design and Layout

In mining operations, the layout of crushing plants and ancillary equipment and structures is a crucial factor in meeting production requirements while keeping capital and operational costs to a minimum. This paper addresses the critical design parameters as well as the consideration of ore characteristics, geographical location, climatic conditions, expected operational life, expansion potential, safety, environment, and operability and maintainability. There are three main steps in designing a good crushing plant: process design, equipment selection, and layout.

Quarry Crushing Circuit

Fine crushing circuits can be more challenging to design than primary crusher installations. There are more equipment options, and each has different installation and maintenance requirements. The process flowsheet dictates the expected performance of the items in the flow stream.

The designer must configure the equipment and structures into a balanced, economical plant design. Screens, feeders, stockpiles, bins, conveyors and crushers must all be interfaced with the most economical supporting structures and buildings. An open-circuit crusher is easier to design and lay out than a closed-circuit design, since it has fewer equipment items and structures.

A well-designed plant layout balances the capital versus operating cost over mine life. Buildings, infrastructure, and major equipment items, represent the major cost elements of a crushing plant. The designer must prepare a layout that suits the design criteria, flowsheet and selected equipment in the most economical possible configuration. It’s important to keep structural costs down, to design for ease of maintenance and operation, and to combine best practices with advances in fabrication and erection. Input from an experienced mining plant structural engineer can be very helpful.

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