Feasibility and advantages of mobile crushing station for industrial tailings treatment

Due to limitations in beneficiation processes and ore grade, large volumes of industrial tailings are generated during mining and ore dressing operations. These tailings require extensive storage areas and often lead to resource waste. Therefore, finding ways to reutilize them is crucial. Crushing tailings is the prerequisite for their reuse—but can modern mobile crushing stations be used for this purpose? Can such an approach bring tangible advantages and value? Let’s explore the possibilities.

Is It Feasible to Use a Mobile Crushing Station?

Those familiar with mobile crushing stations know that their price is relatively high. Therefore, before investing in such equipment, it’s essential to assess whether using a mobile crushing station to process industrial tailings is a viable option. To answer this question, let’s first understand what a mobile crushing station offers.

A mobile crushing station is an integrated, large-scale intelligent crushing system. It eliminates the need for complex infrastructure and instead uses a mobile chassis that is well-suited to the challenging environments where tailings are stored. Its modular and flexible design makes it easy to assemble production lines. With its all-in-one design, it integrates feeding, crushing, conveying, and screening into a single process. Additionally, its smart control system reduces labor needs and boosts operational efficiency.

Therefore, it is entirely feasible to use a mobile crushing station to process industrial tailings.

Tailings Crushing Process Using a Mobile Crushing Station

To clearly understand how effective a mobile crushing station can be in processing tailings, let’s look at the operational flow using the mobile impact crushing station:

1. Tailings are fed into the station’s hopper by an excavator.
2. The heavy-duty grizzly vibrating feeder at the bottom of the hopper performs pre-screening, separating smaller tailings directly as finished products.
3. Larger tailings enter the crushing chamber for processing.
4. Crushed materials are transferred by conveyor to the screening unit for grading.
5. Material meeting particle size requirements is conveyed to the product stockpile.
6. Material that doesn’t meet size requirements is returned via a recirculating conveyor to the feeding hopper for re-crushing.

Production Advantages of Mobile Crushing Stations

In the process of crushing industrial tailings, mobile impact crushing stations offer the following seven key advantages:

1. Crawler-type mobile chassis eliminates the need for piling or foundation work and allows free movement on-site, ensuring convenient relocation.
2. Direct-drive impact crusher enhances energy efficiency.
3. Compact integration of the vibrating screen and crusher results in lower dust emissions on-site and supports environmentally friendly production.
4. Equipped with independent pre-screening and variable-speed feeder, ensuring optimal screening performance even at low feed rates.
5. Hydraulically adjustable impact plates and screen angle (18°–26°) cater to diverse processing requirements.
6. Flexible production line configuration, high productivity (up to 425 t/h), excellent product shape, and enhanced market value of sand and aggregate products.
7. High-end core components, such as Tainida shock absorbers and Siemens motors, ensure durability and simplify maintenance.

Application and Value of Processed Tailings

Industrial tailings processed by mobile crushers can be widely used in various fields, including:

• Construction base aggregates
• Road sub-base materials
• Raw materials for recycled bricks
• Cement-based mixtures
• Dry-mixed mortar

By crushing and reusing industrial tailings, not only is environmental pollution from tailings stockpiles mitigated, but waste resources are transformed into valuable products, improving overall economic returns. As such, this approach represents a promising and sustainable investment.