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The modular station features an aesthetically pleasing and simple structural design; all independent components are detachable, facilitating ease of assembly, disassembly, and transport. It offers flexible configuration options, allowing for the integration of various crushing and sand-making equipment to meet specific client requirements. The station is equipped with access ladders, handrails, and wraparound walkways to facilitate the inspection and maintenance of any part of the main crushing unit.
The KJ Series Mobile Crushing Stations are classified into: Modular Jaw Crusher, Modular Cone Crusher, Modular Impact Crusher, Modular sand making machine, Modular vibrating screen.
The CHUNLEI modular jaw crusher is a self-contained crushing unit mounted on a heavy-duty steel base or rails. It falls between a stationary crushing plant and a fully mobile crusher. It allows for quick on-site installation and easy disassembly, combining flexibility with high performance.
The modular cone crusher production line is a complete prefabricated engineering system. It combines the advanced performance of a cone crusher with a flexible modular design. Specifically designed for secondary and tertiary crushing, it can convert raw materials into stable output and excellent particle shape.
Modular impact crushing plants, with their flexible deployment and rapid installation, can adapt to ever-changing site requirements, ensuring superior performance in the processing of materials such as limestone and construction waste.
Modular sand making equipment offers a modern, efficient, and flexible solution. It can improve project schedules and ensure superior performance. Whether processing raw stone, construction waste, or tailings, it performs exceptionally well.
Modular screening equipment perfectly combines precise grading, efficient screening, and exceptional flexibility. These systems are designed for rapid installation, reducing civil engineering costs and providing flexible solutions for aggregate and ore screening needs.
| Feature / Aspect | Modular Jaw Crusher | Modular Cone Crusher | Modular Impact Crusher | Modular VSI Crusher (Sand Maker) | Modular Screener |
|---|---|---|---|---|---|
| Primary Function | Primary Coarse Crushing: Reduces blasted rock or large ore to a medium size. The first stage in a crushing circuit. | Secondary/Tertiary Crushing: Produces uniform, smaller particles. Ideal for high-hardness materials. | Secondary/Tertiary Crushing & Shaping: Uses impact energy. Ideal for producing high-grade aggregates with cubic shape. | Sand Making & Shaping: Produces high-quality manufactured sand. Optimizes particle shape via “rock-on-rock” principle. | Screening & Grading: Separates materials by size into different specifications. No crushing capability. |
| Working Principle | Compression Crushing: A moving jaw plate periodically approaches a fixed jaw plate, applying immense pressure to fracture the material. | Laminate Compression: A rotating mantle (moving cone) compresses material against a stationary concave (fixed cone), fracturing it through inter-particle compression. | Impact Crushing: A high-speed rotor throws material against impact aprons, fracturing it through high-energy impact forces. | High-Velocity Projectile Impact: Material is thrown at high speed against a lining or material bed, fracturing and shaping through impact and friction. | Screen Mesh Grading: Vibration moves material across a screen surface. Particles smaller than the mesh size fall through, achieving size classification. |
| Suitable Materials | Various ores, granite, basalt, concrete. Hard, abrasive materials with large feed sizes. | High-hardness, highly abrasive materials (e.g., pebbles, granite, iron ore). Ideal for hard rock. | Medium-hard to soft materials (e.g., limestone, gypsum) and brittle materials (e.g., construction waste, concrete blocks). | Both hard and soft rock. Specifically for manufactured sand production and shaping pebbles. Removes flat/elongated particles. | Various dry or wet materials after crushing. Can handle from fine powder to large rocks depending on screen mesh size. |
| Final Product Shape | Good, but may contain some flat or elongated particles. | Uniform shape, but may have slightly higher flakiness compared to impact crushers. | Excellent cubical shape with low flakiness. Preferred for high-quality aggregates. | Best particle shape. Produces well-graded, rounded sand meeting high standards. | Does not change shape. Only sorts by size, producing multiple product specifications. |
| Capacity Range | High. Often the bottleneck. Typically 100-500+ t/h. | Wide range. Tertiary crushing output matches primary. Modular units often 200-400 t/h. | Medium. Approximately 30-500 t/h, depending on model and material hardness. | Relatively lower, focused on fine processing. Example: max capacity around 190 t/h for some models. | High capacity, matching the crushing line. Achieves high throughput with multiple decks. |
| Key Advantages | 1. Robust structure: withstands extreme conditions 2. High capacity: large feed opening, high reduction ratio 3. Low operating costs: electric drive, no engine maintenance | 1. High wear resistance: long liner life for continuous operation 2. Stable operation: consistent product gradation curve 3. High automation | 1. Excellent product shape: meets high aggregate standards 2. Large reduction ratio 3. Handles wet material without clogging | 1. Best yield and shape 2. Adjustable fineness modulus 3. Unique “rock-on-rock” technology: reduces wear costs | 1. Accurate grading: ensures product quality 2. Protects crushers: removes fines to reduce downstream wear 3. Modular design: easy installation and maintenance |
| Typical Layout Position | After the feed hopper. First step in the crushing process. | After the jaw crusher. Second or third step in the crushing process. | Replaces cone as secondary/tertiary, or after a cone crusher for shaping. | After all other crushers. Final step in the sand making process. | Flexible. Pre-screening (before crushing) or check screening (after crushing). Often the final output stage. |
Choose a Jaw Crusher if: You need to process large, hard, abrasive rock (e.g., granite, basalt) as the first stage of your production line. It is the most reliable and efficient choice.
Choose a Cone Crusher if: You are processing high-hardness materials for continuous, high-load production. It offers lower cost per ton.
Choose an Impact Crusher if: Your material is medium-hard (e.g., limestone) and you have high requirements for cubical aggregate shape.
Choose a VSI Crusher if: Your core need is producing high-quality manufactured sand, whether from crusher fines or pebbles. It is the ideal choice.
Choose a Screener if: You need to separate materials into 2-5 different size specifications, or pre-remove fines to protect downstream crushers. It is an essential companion.
Q: What materials are suitable for crushing with a modular jaw crusher?
A: Primarily used for primary crushing of various hard ores and rocks with a compressive strength not exceeding 320 MPa, such as granite, basalt, and limestone.
Q: How long does installation take?
A: Due to the pre-designed steel frame structure, on-site assembly and commissioning can usually be completed in just 2-3 days, several weeks faster than traditional fixed installations.
Q: What are the main uses of a modular cone crusher?
A: Used for medium and fine crushing operations, processing materials from jaw crushers. Suitable for high-hardness, highly abrasive stones, such as iron ore and river pebbles.
Q: What scenarios are suitable for the modular design of impact crushers?
A: Suitable for secondary or tertiary crushing of medium-soft to medium-hard materials (such as limestone and concrete waste), producing good particle shape, commonly used in aggregate production and recycling.
Q: What are the main uses of a modular vertical shaft impact crusher?
A: Used for artificial sand making and stone shaping, it can process 5-40mm crushed stone into well-graded manufactured sand, suitable for concrete mixing plants and dry-mixed mortar production lines.
Q: Can the modular screening machine be used alone?
A: Yes. It can be used independently for material grading, or it can be used in conjunction with various modular crushers to form a complete modular crushing and screening production line.
Q: Is it easy to move?
A: Very easy. The entire equipment is fixed on a steel frame and can be transported as a whole using a flatbed truck, suitable for rotating operations across multiple construction sites.
Chunlei Mining Machinery
