The throughput of a crushing line during irregular loader operation is calculated using a formula incorporating various coefficients; this takes into account equipment downtime and adjustments for different crushers, and there are ways to improve this figure.
To install a mobile crusher at a quarry, a site is required with a gradient of no more than 3°, a topographical survey with a 5-metre grid, a deviation of 2 mm/m, drainage channels with a gradient of ≥0.5%, and ground supports with a safety factor of 1.5.
At urban noise-controlled sites, the processing of reinforced concrete is carried out using four solutions: a hydraulic jaw crusher, 120-mm sound barriers, rubber pads on the screen, and operating procedures — all of which comply with health and safety standards.
To produce road aggregate, basalt is crushed in four successive stages with intermediate screening, using jaw, cone and centrifugal impact crushers, as well as a vibrating screen, in accordance with national standards.
The design of a mobile crushing plant for coarse granite involves determining the input parameters, selecting a jaw crusher, coordinating the throughput capacity of the units, and verifying compliance with Russian Federation transport regulations.
Obtaining a stable fraction from overburden involves preliminary sorting into three groups, separate crushing using suitable crushers, re-sorting and reprocessing of substandard material; it is not recommended to skip the preliminary sorting stage.
For processing a mixture of broken bricks, gypsum, wood and plastic in accordance with the 2025 tests, a twin-shaft crusher with a gap of 15–35 mm and a shaft speed of up to 30 rpm is optimal.
A standard magnetic separator removes 92–97% of ferrous metal from concrete with a particle size of 0–30 mm, depending on the particle size, conveyor speed and dust levels; it does not capture non-ferrous metals and requires additional maintenance.
A magnetic separator is essential when processing reinforced concrete: it extracts ≥98% of steel, meets the standards for recycled aggregate, and reduces equipment wear by 40–60%. An overhead conveyor-mounted model with neodymium magnets is suitable; conveyor speeds exceeding 1.8 m/s reduce efficiency.
Under normal operating conditions, the risk of reinforcement wire becoming entangled in the rotor <2%, conveyor damage <1.2%. The risk is increased by a large clearance, high speed and heavy fittings; preventative measures significantly reduce the risk.
