Mining Crusher Plant Configurations and Leading Chinese Brands

Yuxuan

2026-01-17 18:09:56

In mining, crushers are rarely used in isolation. They are integrated into complete systems or "plant configurations" designed to efficiently process ore from the mine face to the mill feed. The configuration depends on the ore type, mine plan (open-pit vs. underground), required capacity, and product size. Chinese manufacturers now offer comprehensive solutions for all major mining crushing configurations.

1. Common Mining Crusher Plant Configurations

These configurations define the crushing flow and equipment layout.

Single-Stage Crushing (Primary Only):
- Flow: ROM Ore → Primary Crusher (Gyratory/Jaw) → Conveyor to Stockpile or Next Process.
- Application: Simple operations where primary crusher product is acceptable for leaching, waste rock, or direct shipping ore (DSO).
Two-Stage Crushing (Primary + Secondary):
- Flow: ROM Ore → Primary Crusher → Conveyor → Secondary Crusher (Cone) → Conveyor to Stockpile/Mill.
- Application: Most common for medium-hard ores requiring a finer feed for grinding (SAG/Ball Mills).
Three-Stage Crushing (Primary + Secondary + Tertiary):
- Flow: ROM Ore → Primary → Secondary → Tertiary Cone Crusher(s) → Fine Ore Stockpile.
- Application: For hard, abrasive ores (like some copper, gold ores) where a very fine crusher product (e.g., -12mm) is needed for efficient grinding.
In-Pit Crushing and Conveying (IPCC) - Semi-Mobile/Fully Mobile:
- Flow: ROM Ore from shovel → Mobile/Semi-Mobile Primary Crusher in the pit → Direct conveyor to process plant or secondary station.
- Application: Large open-pit mines to replace truck haulage, significantly reducing operating costs. The crusher is relocated periodically.
Underground Primary Crusher Station:
- Flow: Ore from LHDs or trains → Underground Primary Crusher (often a jaw or gyratory) → Ore pass or conveyor to surface.
- Application: Underground metal mines to reduce ore size for hoisting or conveying to surface.

2. Leading Chinese Brands for Mining Crusher Plants

These companies provide not just crushers, but engineering and complete system solutions.

Metso Outotec (Nordberg®, but with strong local manufacturing & engineering in China): Global leader, provides all configurations.
- Models: Superior™ Gyratory Crushers, Nordberg® HP Series Cone Crushers.
Sandvik Mining and Rock Solutions (with Chinese operations): Another global giant with local presence.
- Models: CH/CS Series Cone Crushers, CJ Series Jaw Crushers.
NFLG (南方路机 - Focus on Mixing & Crushing): Offers complete stationary and mobile crushing stations.
Shanghai Shibang Machinery (SBM): Major supplier of crushers and complete plants.
- Models: HPT Multi-cylinder Hydraulic Cone Crusher (for secondary/tertiary), C6X Jaw Crusher (for primary).
Liming Heavy Industry (郑州黎明重工):
- Models: HST Single Cylinder Cone Crusher, HPT Multi-cylinder Cone Crusher, PE/PEW Jaw Crushers.
SANY Mining (三一矿机): Specializes in heavy mining equipment, including mobile and semi-mobile crusher stations.
- Models: SANY SKT Series Semi-Mobile Crushing Station.
Zoomlion Mining (中联矿机):
- Offers complete crushing plant solutions for mines.
XCMG Mining (徐工矿机):
- Manufactures large mining equipment, including potential for IPCC systems.
Zhongxin Heavy Industry (上海世邦机器 -关联):
- Specializes in cone crushers and complete crushing lines.
Shenyang Sanland (沈阳山力): A licensed manufacturer of Nordberg® crushers in China, providing reliable alternatives.

Mining Crusher Configuration and Model Examples Table

Plant Configuration	Typical Crusher Roles	Chinese Brand & Model Example (for role)	Key Feature for Mining
Two-Stage Crushing Plant	Primary Jaw, Secondary Cone	Primary: Liming PE1200×1500 Jaw Crusher Secondary: SBM HPT300 Cone Crusher	Balanced for medium-hard ore, reliable flow for mill feed.
Three-Stage Crushing Plant	Primary Gyratory/Jaw, Secondary Cone, Tertiary Cone	Primary: Shenyang Sanland (Nordberg-type) Gyratory Tertiary: Zhongxin Heavy XHP500 Cone Crusher	Produces very fine feed for ball mills, handles hard & abrasive ore.
Semi-Mobile IPCC (In-Pit)	Semi-Mobile Primary Gyratory/Jaw	SANY SKT150 Semi-Mobile Crushing Station (with gyratory or jaw)	Designed for relocation, integrates feeder, crusher, discharge conveyor on a movable frame.
Underground Primary Station	Underground Primary Jaw Crusher	Liming PE900×1200 Heavy-Duty Jaw Crusher (configured for underground)	Compact and robust design for limited space, dust control features.
Complete Plant w/ Pre-Screening	Grizzly Feeder, Primary Jaw, Secondary/Tertiary Cones	NFLG Complete Stationary Crushing & Screening Plant	Integrated design with grizzly to remove fines, improves overall efficiency.

3. Critical Ancillary Equipment in Mining Configurations

A crusher plant includes more than just crushers:

Feeders: Apron feeders for primary crushers (handle large, heavy ROM ore), vibrating grizzly feeders (VGZ) to scalp fines.
Conveyors: Heavy-duty belt conveyors to transfer material between stages and to stockpiles.
Screens: Scalping screens (before primary), sizing screens (between secondary/tertiary, closed-circuit crushing).
Dust Suppression/Collection: Essential for environmental compliance and worker health, using water sprays or baghouses.
Electrical & Control Systems: PLC-based automation for coordinated startup, shutdown, and monitoring.

Conclusion: Modern mining crushing is about integrated system configurations rather than individual machines. For standard surface mines, two or three-stage fixed plants using robust cone and jaw crushers from brands like SBM, Liming, or licensed manufacturers like Shenyang Sanland are common. For cost and efficiency leadership in large open pits, semi-mobile IPCC systems from SANY Mining are a key offering. While global giants (Metso, Sandvik) dominate the high-end technology space, Chinese manufacturers now provide capable, reliable, and cost-competitive complete solutions for a wide range of mining applications, from primary crushing stations to complex multi-stage plants.