100 tons mobile crusher

Overview of the 100-Ton Mobile Crusher

The 100-ton mobile crusher represents a significant class of equipment in modern quarrying, mining, and construction recycling operations. As a track-mounted or wheeled unit with an integrated crushing mechanism, its primary advantage lies in its mobility and self-sufficiency, allowing it to be moved between sites or within a large site with relative ease. This eliminates the need for fixed foundation construction and extensive material haulage from the face to a stationary crusher, offering substantial savings in time and operational costs. Typically equipped with powerful diesel engines and hydraulic systems, these crushers can process a wide range of materials—from hard rock to demolition concrete—directly at the source. The "100-ton" designation generally refers to the machine's operating weight, indicating its substantial size and robust crushing capacity, which often correlates with an output ranging from 200 to over 500 tons per hour depending on the material and specific model.

Key Features and Comparisons

A 100-ton class mobile crusher is not a single machine but a category encompassing different crushing technologies. The two most common types are Mobile Jaw Crushers and Mobile Impact Crushers (or Cone Crushers), each suited for specific applications.

Feature	Mobile Jaw Crusher	Mobile Impact Crusher
Primary Application	Primary crushing (first reduction stage) of hard, abrasive materials (e.g., granite, basalt).	Primary or secondary crushing of softer, less abrasive materials (e.g., limestone, recycled concrete, asphalt). Excellent for shape correction.
Crushing Principle	Compression force between a fixed and a moving jaw.	Impact force from rotating hammers/blow bars against aprons/liners.
Output Shape	More elongated, slabby product (can require secondary crushing for quality aggregates).	More cubical, well-shaped end product, often in a single stage.
Wear Part Cost	Generally lower for processing very hard rock.	Can be higher when processing abrasive materials due to faster wear of blow bars and aprons.
Typical Use Case	Large-scale granite quarry feeding a stationary plant.	Construction & Demolition (C&D) waste recycling on an urban redevelopment site.

Real-World Application Case: Urban Redevelopment Project

A prominent real-world application can be illustrated by projects like the redevelopment of major infrastructure or brownfield sites. For instance, during the clearance phase for new commercial districts or stadiums (e.g., projects akin to London's King's Cross redevelopment or Olympic Park construction), vast amounts of concrete and asphalt rubble are generated.

A contractor might deploy a 100-ton class mobile impact crusher directly on-site. The process involves:

1. Pre-sorting: Demolished concrete and masonry are sorted to remove major contaminants like wood and metal.
2. On-site Crushing: The mobile crusher is set up adjacent to the rubble piles. Excavators feed the material into its hopper.
3. Direct Re-use: The crusher processes the material into specified aggregate sizes (e.g., 0-40mm). An integrated magnetic separator removes rebar.
4. Product Utilization: The crushed aggregate is immediately used on-site as sub-base for new roads, parking lots, or backfill material.

This closed-loop solution drastically reduces truck traffic for hauling waste away and importing virgin aggregate, leading to lower carbon emissions, significant cost savings (up to 50% in aggregate procurement), and faster project timelines.

Frequently Asked Questions (FAQ)

1. What powers a 100-ton mobile crusher?
   Almost all modern units in this weight class are diesel-hydraulic hybrids. A high-horsepower diesel engine drives hydraulic pumps that power all key functions: the tracks for movement, the crusher itself (via hydraulic motors or direct drive), conveyors, screens, and adjustment mechanisms.

2. Can it really operate anywhere on site?
   While highly mobile, it requires a reasonably prepared ground surface that is stable enough to support its immense weight (~100 tons). It is not an off-road vehicle for soft mud but is designed to traverse typical quarry or construction site terrain under its own power.

3. How does it compare economically to a fixed crushing plant?
   The economic advantage is not in pure hourly output cost but in total project cost flexibility. A fixed plant has higher upfront installation costs but lower operating cost per ton for very long-term (>5 years), single-location projects. The mobile crusher excels where projects are shorter (<2 years), sites change frequently, or material needs to be processed at multiple points within a large site.

4. What are the major maintenance concerns?
   Primary maintenance focuses on wear parts: jaw plates/mantles/liners and blow bars/hammers/aprons depending on crusher type; screen meshes; conveyor belts; and hydraulic system integrity (hoses, filters). Daily greasing of bearings and regular engine servicing are critical preventative measures.

5. Is one operator sufficient?
   Typically yes for basic operation of the crusher itself from its control panel or remote control. However,a full working circuit usually requires additional personnel: at least one excavator operator to feed the hopper,and often a wheel loader operator to manage stockpiles of feed material or finished product.The total crew size depends on the scale of the overall material handling operation