In the field of mining quarries, sand and aggregates production, and construction waste recycling, the classic scheme of the separated production line was always limited by several operational issues.On-site assembly and welding of loose components increase the installation period and capital occupation. Further expansion and upgrade of the technological process will require significant modification of the civil engineering base and steel constructions, leading to considerable production losses. Contamination of the raw materials by steel items results in frequent unexpected shutdowns and repairs. The lack of unified service platforms complicates servicing and increases labor consumption. Also, due to the absence of the safety protection system, the costs of safety audit and improvement increase.
The MU116J Jaw Modular Crushing Station is based on the MP modular crushing and screening system. Due to the integrated preassembled frame design, all these problems are solved in the best way. The station can work independently or be combined with any other MP-series units to create a full-fledged production line. This equipment can be used in three main application scenarios: Open-pit metal and non-metallic mines for primary crushing of the raw ore; Construction of new sand and aggregate production lines and the upgrade of the existing ones; Preliminary processing of demolition waste for recycling. The standard electromagnetic separator automatically filters out the steel impurities from the material, which provides reliable protection of the whole production process.
This complete solution has four unique advantages: efficient investment return, high performance, maintenance cost optimization, and safe production expansion. The complete machine is pre-assembled and connected to electricity at the factory. Upon arrival at the construction site, you only need to install and connect it to the electricity to start operation. Standardized container transport significantly reduces the period of delivery and construction of the project, enabling it to obtain finished products faster and shorten payback periods. The core PEV116 jaw crusher is designed with the use of the large stroke and steep toggle plate construction, with the dual-motor grizzly feeder and wide discharge conveyor belt guaranteeing consistent output within the whole range of the feed size. The discharge opening is adjustable in accordance with the finished product parameters. All high-wear parts of the main frame are equipped with preinstalled liners. Integrated maintenance platform and ladder allow replacing the worn parts without the use of additional supporting constructions. The electromagnetic separator, installed on the front of the station, prevents the metal objects from entering into the crushing chamber and damaging its construction, thus reducing the spare parts usage and downtimes. The complete machine is delivered with the safety guardrails, maintenance platforms, and emergency stop systems installed, which immediately meet the industrial standards of safety. The standardized universal base makes it possible to further expand the technological line with secondary crushing and screening stations without destruction of the initial construction.
Equipment Component | Name | Supporting Power (kW) | Single Unit Weight (kg) | Configuration Description |
— | Feed Hopper | — | 3800 | Large-capacity material buffering hopper, reducing frequent feeder start-stop cycles |
MVF1242 | Grizzly Feeder | 14 | 3800 | Dual-motor drive, uniform material distribution, preliminary screening of fine materials |
PEV116 | Jaw Crusher | 132 | 21500 | Core primary crushing unit featuring large-stroke high-efficiency crushing structure |
RCDB-08 | Electromagnetic Separator | 5.5 | 980 | Standard configuration, front-mounted iron removal system protecting the complete process |
MW120J-40-00 | Main Discharge Conveyor Assembly | 11 | 3700 | 1200 mm wide × 8.5 m sheet-metal conveyor belt with large conveying capacity |
— | Structural Components | — | 9500 | Integrated modular load-bearing frame structure |
Engineering Parameter Analysis
The total installed power of all major components | 162.5 kW |
The overall machine weighs | about 43,280 kg. |
Power distribution is optimized according to the practical loading:
The 132 kW jaw crusher bears the main crushing workload, while the feeder, conveyor, and the electromagnetic separator are auxiliary low-power systems that help to avoid unnecessary installed power and save electricity.The weight of all components is optimized during pre-assembly at the factory. The frame guarantees the balanced load distribution, enabling the stable single-point lifting performance when installing on-site without any risk of the frame deformation and equipment dislocation.Dual-motor grizzly feeder enables variable-frequency feeding control. It helps to reduce the impact of big stones and preliminary removal of soil and fine materials, preventing their accumulation inside the crushing chamber.
Adjustment of Closed-Side Setting (mm) | 70 | 80 | 90 | 100 | 125 | 150 | 175 |
Instantaneous Processing Capacity (t/h) | 165-205 | 205-255 | 225-285 | 270-345 | 320-405 | 370-465 | 410-520 |
Engineering Parameter Analysis
The capacity is directly proportional to the discharge opening adjustment range.The small size discharge opening adjustment of 70 mm is suitable for primary crushing pre-processing which requires fine aggregates, while the large size opening adjustment of 175 mm is suitable for high capacity primary crushing of raw mine materials.The capacity fluctuation range is normal fluctuation because of different hardness, water content, and size of the input material.Customers can make use of the capacity range and the characteristics of their own raw materials to choose downstream equipment selection which can match the capacity of subsequent screening and crushing units.This will avoid the bottleneck, material accumulation and equipment utilization mismatch between upstream and downstream process due to capacity mismatch.
For the different level of automation and specific site condition, the equipment provides the following six kinds of optional supporting accessories.Those accessories can be selected by customers according to actual project requirements without affecting the modular structure of the main equipment.
The extension of feeding hopper makes the effective volume increase and reduces the feeding frequency of the loader.Suitable for the sites with relatively low frequency of loader unloading.
Without manually shim adjustment.It allows fast and remote adjustment of discharge opening and is suitable for production scenarios requiring the switching between different aggregates frequently.
Provides remote control of the equipment start/stop function and speed adjustment.It makes the requirement of site manual operation lower and improves the automation of production.
Detects the material storage height of hopper in real time.And the system connects with the feeder speed adjustment system automatically and avoids empty hopper and material overflow.
Provides sufficient lighting for the production during night shift.Improves the safety condition of equipment operation and maintenance during night shift.
Real-time monitoring the incoming material size, material blockage situation, and any possibility of steel contamination.Enables operators to take the measures in advance to avoid equipment damage.
Every functional module can be disassembled and transported in a standard container.Compared with the traditional bulk transportation of disassembled equipment, the modular design saves more transportation batches and achieves higher transportation efficiency.When reaching the site, the installation of the equipment only needs lifting and alignment and the simple electrical wiring.The procedures like traditional welding on-site, steel structure assembly, and wiring in many places have been removed.The delivery and production process cycle of the equipment is shortened, which helps the project to get income earlier.
The base interface of all MP series equipment is unified standardized.The MU116J jaw crusher module is not just suitable for its independent operation but also seamless connection with other MP series modules, including the cone crusher, VSI crusher, and multi-deck screening modules.This allows the quick formation of the complete multi-stage crushing and screening production line.In case of expanding the existing plant or process upgrading, there is no need for destructive modification of the base or steel structure of the existing equipment.It can reduce shutdown loss of transformation project greatly.
The whole frame layout of complete machine has been optimized through engineering design.The sufficient operating space is reserved around every wear part, including crushing module, feeder, belt conveyor and electromagnetic separator.The equipment is equipped with the integrated maintenance platform and ladder.When replacing the wear parts like jaw plate, conveyor belt and liner, no need to set up scaffolding and remove surrounding equipment.Efficient maintenance can be made and downtime can be reduced greatly.
The MU116J is developed based on the mature modular design of MP series.
The equipment is proved its good performance under various mining and construction waste recycling application situations.Its structural strength and crushing performance are proved through field operation for a long time.The key components including motor, transmission system, and electrical control system are provided by recognized brands.Every complete machine finishes the comprehensive test before shipping.The possible problems can be found and eliminated in time before delivery.
Q1: How much time does on-site installation of this modular crushing station usually take? How much time can it save in comparison with a traditional jaw crusher installation?
A:The whole machine finishes factory assembling and electrification before delivery. After reaching the installation site, the process of lifting, electrification, and commissioning remains.In contrast to traditional separate equipment installation processes, MU116J saves lots of time-consuming work like steel structure welding, separate equipment assembling and multilevel cable installation.Overall, the installation and commissioning time can be considerably shortened, and this allows the project to start production as soon as possible and to avoid financial losses due to the high cost of renting the site and its downtime.
Q2: In case of an upgrade of the old aggregate production line, is it possible to replace the old primary crushing unit with the MU116J? Will it require substantial civil modifications?
A:The equipment uses the standard modular base of the MP series.It does not require major excavations and concrete foundation construction.The module will be able to integrate easily with existing downstream conveyor and screening systems. This significantly reduces the amount of civil works and downtime.It is highly convenient for renovation of existing aggregate plants.
Q3: In case of processing construction waste that contains a significant number of steel reinforcement elements, will the standard RCDB-08 electromagnetic separator provide enough protection for the jaw crusher main unit?
A:The equipment has the RCDB-08 electromagnetic separator as a standard configuration.It continuously separates steel bars, steel plates and other ferrous materials contained in incoming materials.By excluding metal materials from entering the crushing chamber, the system prevents the occurrence of impact damages of jaw plates and toggle plates.This significantly reduces risks of abnormal damage, emergency repairs and downtime.Electromagnetic separator is a standard protection device in case of construction waste recycling applications.
Q4: If there will be an expansion of the production line in the future in addition to cone crushers and screening modules, is any modification of MU116J frame required?
A:No modification of the MU116J main frame is required.The whole machine has a unified standard connection base and can be connected to MP series cone crushers, vertical shaft impact crushers, and screening modules.The modular design gives great flexibility in future expansion of the system.In the case of future expansion of production capacities, no cutting, reinforcement and reconstruction of existing steel structure will be needed.
Q5: In case of replacement of wear parts (jaw plates, liners) during maintenance operations, is any scaffolding required?
A:The whole machine has integrated maintenance walkway, ladders and platform.There is enough space left around the wear parts area.Replacement of different wear parts can be accomplished without temporary scaffolding.Basic maintenance work can be done efficiently by one operator. This significantly reduces maintenance time per each service cycle.
Q6: In case of different rock hardness and moisture content of raw material, how can the appropriate closed-side setting be chosen? What is the reference capacity range for this?
A:In case of harder raw material or higher moisture content of raw material, it is recommended to choose capacity planning closer to the lower end of the range for the chosen discharge opening size.In case of softer and drier raw material, equipment capacity planning can be done closer to the upper capacity range.Smaller 70 mm discharge opening is suitable for primary crushing with fine aggregate output.Large 150-175 mm discharge opening is suitable for high-capacity primary crushing of mine raw material.Customers can choose the proper discharge opening depending on their own raw material properties and production requirements.
Wherever your worksite is located, whatever your equipment specifications require, and no matter how severe the operating conditions — MP Crusher delivers the equipment, the solution, and the performance you need. Our equipment is already at work in more than 20 countries around the world.
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