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Crushing stations

Reduce costs and emissions with FLS primary crushing stations

Mines aren’t static, so why should the crusher stay still? Our primary crushing stations move with the mine face, reducing material transportation costs and emissions. These flexible, high-throughput solutions are customised to the conditions and application to deliver the productivity you need.

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Key benefits of our primary crushing stations

  • Reduce construction costs and time

    Our primary crushing stations are delivered in preassembled plug-and-play modules for fast and easy erection onsite. Just hook it up to a power and water supply, connect it to the mine control system, and you’re on your way. There’s also no need for the extensive civil construction needed by traditional crushing installations. In addition to cutting costs and construction-related emissions, this approach mitigates the safety and commissioning risks inherent to onsite erection work, with full system performance guaranteed by us.

  • Outsource the hassle of implementing a complex system

    Crushing stations are complex systems that require knowledgeable and experienced hands to implement. When you select one of our primary crushing stations, our team of market-leading experts takes on that responsibility and delivers a hassle-free crushing solution. You receive a complete process solution from an OEM with a long track record supplying both crushing equipment and process design. This is particularly relevant in regions where the requisite skills and labour are in short supply.

  • Adaptable to all mining conditions

    We have built primary crushing stations on all continents (except Antarctica) and in all climate conditions – from very hot down to -40°C. This experience ensures we can adapt the technology to any set of environmental conditions, applications, and ore characteristics found at a mine site. This includes complying to all necessary standards and regulations, including adapting the electric system to the local standard.

Our primary crushing stations 

Combining high throughputs with the flexibility of a mobile crushing plant, our primary crushing stations provide an ideal solution for in-pit crushing and conveying operations. We supply both direct- and indirect-fed systems, customised to your application, whether that’s working with soft, medium or hard ores. These modular plants are built on a steel base, which rests on a pontoon, enabling them to be moved at any time using transport crawlers or self-propelled modular transporters.

Models

Comparison of our primary crushing stations

Direct-fed crushing station
Indirect-fed crushing station
Capacity
Up to 14,000 tph
Up to 14,000 tph
Total plant weight
Up to 2500t
Up to 2500t
Feeding equipment
Crusher feed hopper.
Receiving hopper + apron feeder.
Crusher
Gyratory crusher
Any primary crusher
Screen
None
Pre-screening possible

Equipment features of our primary crushing stations

  • Hydraulic rock breaker

    Handles oversized lumps, cleaning mps and cleaning of crusher blockages/bridging in the crusher, and is .used for maintenance during concave exchanges..

  • Enclosed equipment compartments

    Protect lubrication systems, hydraulics, and other auxiliaries against dust and damage.

  • Motorised maintenance trolley

    Enables safe inspection of hydraulic pipes and maintenance hydraulic cylinder.

Full process automation for crushing stations

Enables safe inspection of hydraulic pipes and maintenance hydraulic cylinder.

Crushing stations can be provided either partly or fully enclosed.

A personnel elevator can be provided to aid access on stations with high elevations.

Electromagnets/metal detectors can be supplied for the removal/detection of tramp metal.

Onboard electro-hydraulic jib or bridge crane up to 150t lifting capacity.

Maintenance & service of our crushing stations

Our aftermarket support includes the supply of consumables, professional services, spares, and upgrades, as well as innovative digital solutions designed to reduce your environmental impact and operating costs.

Learn more about FLS service centres

Frequently asked questions

FAQs for crushing stations

A primary crushing station is the first stage in mineral processing operations. It prepares ROM material for conveying and further processing, usually via secondary crushing and screening, where material is readied for subsequent grinding and flotation. 

A semi-mobile crushing plant is one that can be periodically relocated closer to the mining operations. This compares with stationary crushing stations and fully mobile systems, which are track-mounted to allow them to continuously follow excavation equipment.

Semi-mobile crushing plants comprise a truck ramp and tipping point, which feeds into the main crusher (if direct fed) or a feed bin (if indirect fed). Material moves through the crusher and drops onto a discharge conveyor. Additional components may include a rock breaker, jib or alternative crane, elevator, and tramp metal detector or electromagnet. Our crushing stations rest on large pontoons on a compacted gravel bed, without anchoring, to allow easy relocation using transport crawlers or self-propelled modular transporters.

The best crusher for primary crusher will depend on the material being processed and the requirements of the operation. In our experience, direct-fed gyratory crushers offer the optimum solution for most mining applications; however, alternative indirect-fed crushing options are available, including jaw crushers, double roll crushers, ABON® sizers, and the Eccentric Roll Crusher.

FLS primary crushing stations can handle capacities up to 14,000 tpd.

It takes six to eight months to erect an FLS primary crushing station onsite, depending on site conditions and the level of pre-erection and modularisation.

The size of our primary crushing station modules depends on several detailed design criteria, including the size of the plant, the level of modularisation, and transport limitations.

Delivery time for a primary crushing station is about 12-14 months from contract acceptance.

Relocation time for a FLS semi-mobile crushing plant depends on a broad range of factors, including the level of modularisation, distance between locations, working time, and method to transportation.

Screens are only required for indirect-fed primary crushing stations. Here, heavy-duty grizzly screens are used.

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