The cost price per tonne of crushed stone depends on fuel consumption and downtime (factor 42-68%), and amounts to 120–380 roubles/t; fuel consumption meters and downtime logs are taken into account; unscheduled downtime increases the cost by 15–22%.
When processing ferruginous quartzite, a combination of primary screening and a jaw crusher is more effective than a single crusher: it offers higher efficiency on the 27%, reduces the load on the crusher and minimises over-grinding, and delivers higher throughput.
For continuous crushing of wet limestone containing clay, use a crusher with the following specifications: feed opening 180 mm, vibrating feeder 12 mm, shaft speed 210 rpm, blow-off pressure 0.6 MPa; maximum moisture content 18%; if the clay content is 15%, increase the amplitude to 15 mm.
Field and laboratory tests have shown that, when crushing slag, this process outperforms limestone in terms of durability and yield of the target fraction, whilst exhibiting less sticking and wear, and lower energy consumption on the 18%.
The hammer crusher is suitable for granite containing ferrous inclusions of up to 12%: the crushing ratio is 8:1, and the hardened steel hammers have a service life of 210 hours based on an 8-hour working day. If the content exceeds 18%, the proportion of oversize material exceeds 22%.
A single mobile plant processes concrete containing reinforcing bars (extracting 98% of reinforcing bars) and asphalt in sequence; with mode switching taking up to 15 minutes; the finished aggregate has a particle size range of 0–40 mm with impurities of up to 1.2%.
According to tests carried out between 2023 and 2025, the jaw-and-cone combination is more durable and cheaper to operate for basalt, and produces less waste; however, the jaw-and-rotary combination is more cost-effective for small volumes and where there is a high proportion of cuboid grains.
When processing limestone, the production cost per tonne for a jaw crusher is 12–28 roubles lower than for a rotary crusher. Where quartz impurities are present at levels of up to 7%, this difference increases to 35–42 roubles. A rotary crusher is more cost-effective for annual volumes exceeding 120,000 tonnes.
Annual expenditure on hammers, liners and bearings for a crusher (50 t/h, 8 hours per day) average 128,000 roubles: hammers 57%, linings 32%, bearings 11%. Replacement intervals: 1,400, 2,100 and 4,200 hours respectively. Costs increase with higher loads and when processing abrasive materials; scheduled maintenance reduces expenditure.
The annual budget for spare parts for a mobile crusher (2,000 hours per year) is 12,000–18,000 euros, with 65–70% being spent on wear parts for the crushing chamber. The amount depends on the hardness of the raw material, the load and the quality of maintenance.
