An iron ore crushing plant is a critical, capital-intensive component of any mining operation, responsible for reducing mined Run-of-Mine (ROM) ore into a conveyable and mill-feed sized product. The selection of a manufacturer for such a plant is not merely an equipment purchase; it is the establishment of a long-term partnership that impacts the entire lifecycle cost, operational efficiency, and profitability of the mine. This datasheet serves as a structured guide for project engineers, procurement managers, and mining executives to evaluate and select manufacturers based on comprehensive technical, commercial, and service criteria. It moves beyond simple equipment lists to encompass the holistic capabilities required for designing, delivering, and supporting a high-availability system capable of handling the extreme abrasiveness and variability of iron ore.
A reputable manufacturer must demonstrate mastery across these domains:
2.1 Plant Design Philosophy & Process Engineering:
2.2 Key Equipment Specifications & Technological Edge:
Manufacturers are often distinguished by their proprietary equipment or deep application knowledge.
Primary Crushers:
Secondary & Tertiary Crushers:
Feeders & Screens:
2.3 Ancillary Systems Integration:
A plant is more than crushers; it’s an ecosystem.
This section forms the core evaluation checklist.
| Evaluation Category | Key Criteria / Questions for Manufacturer | Industry Benchmarks / Red Flags |
|---|---|---|
| Company Profile & Experience | • Years in business specializing in mining crushing. • Number of iron ore plant references (>5 Mtpa capacity). • Financial stability. • Global service network footprint in mining regions. |
Look for >30 years history. Demand site-visitable references in similar geographies/climates. Avoid manufacturers with limited aftermarket support near your site. |
| Engineering Depth | • In-house engineering team size dedicated to process design. • Use of Finite Element Analysis (FEA) on structural components. • Ability to provide lifecycle cost analysis models. • BIM (Building Information Modeling) capability. |
Insist on seeing FEA/DEM simulation reports specific to your ore data. Lack of LCCA tools indicates a transactional not partnership approach. |
| Supply Chain & Manufacturing | • Location(s) of key fabrication facilities. • Quality control certifications (ISO 9001). • Sourcing strategy for critical components (bearings, motors). • Capacity to handle large-scale plate work (>150mm thick). |
On-site inspection of fabrication shops is recommended over-reliance on outsourced major assemblies can risk quality consistency |
| Project Execution | • Detailed project methodology from order-to-commissioning. • Proven record of on-time delivery within +/- 5%. • Health Safety Environment policies during installation. • Training programs offered for client operations/maintenance staff. |
Request detailed Gantt charts from past projects verify completion certificates from clients poor safety records are a major red flag |
| After-Sales Support Performance Metrics Guaranteed spare parts availability (% >95%) Mean Time To Repair MTTR targets Field service engineer response time commitment Performance-based service contracts offered Warranty period standard vs extended options Red Flags Lack regional parts warehouse No remote diagnostic capability Only offer reactive not predictive maintenance contracts |
The lowest capital CAPEX quote often leads to highest operating OPEX
Capital Expenditure CAPEX Equipment purchase price Freight insurance duties Civil works scope included if any Erection commissioning supervision costs Spare parts initial inventory package Operating Expenditure OPEX Energy consumption per ton crushed predicted Wear parts consumption cost per ton Liner changeout downtime labor costs Planned maintenance labor costs Over 15 years OPEX typically constitutes 60-70% TCO making performance guarantees critical
Performance Warranties Guarantees Manufacturers should provide contractual guarantees subject to penalties
Throughput Guarantee Tons per hour over specified period Product Size Distribution P80 P95 consistency Liner Wear Life Guarantee Hours or tons processed between changes Overall Plant Availability Typically >92% excluding planned stoppages
Leading manufacturers are innovating in areas crucial modern mining
Digitalization Smart Plants Integration sensors providing realtime data pressure power draw leading predictive analytics platforms Digital twin technology simulate performance plan maintenance Automation Full autonomous crusher setting feed rate optimization robotic solutions liner changeouts reducing downtime safety risks Energy Efficiency Development high efficiency drives regenerative conveyor systems crusher designs reduce kWh ton target <0 8 kWh ton Sustainable Design Noise dust emission reduction designs water recycling systems within plant circular economy principles
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