1.Work efficiency comparison
1.1Analysis of the work efficiency of crushing buckets
Crushing buckets are usually installed on excavators and work with the help of the hydraulic power of the excavator. Its working principle is to drive the eccentric spindle through the hydraulic motor to cause the movable jaw plate to move up and down periodically, thereby performing crushing operations such as squeezing and rubbing the material. Taking Motek MTC200 crushing bucket as an example, with inlet opening 930mm*460mm,when working with a 24-ton excavator, the output per hour can reach about 25 tons. If calculated as 8 hours a day, the daily output is about 200 tons.
In actual application scenarios, the crushing bucket shows unique advantages in small construction sites or narrow areas of the site. In urban road repair projects, the construction site is often limited in space, and large equipment is difficult to use. At this time, a small excavator equipped with a crushing bucket can flexibly shuttle between construction sites and timely crush the demolished concrete blocks, old road materials, etc., which greatly improves the construction efficiency and avoids a lot of time and manpower consumed in material handling.
1.2 Analysis of the working efficiency of mobile crusher
Mobile crusher is an integrated crushing equipment, usually composed of multiple parts such as feeder, crusher, screening machine, belt conveyor, etc., which can be flexibly configured according to different crushing needs. Its working process is that the material is evenly transported to the crusher for crushing through the feeder, and the crushed material is sent to the screening machine for screening through the belt conveyor. The material that does not meet the particle size requirements will be returned to the crusher for re-crushing.
The output of mobile crusher varies greatly due to different models and configurations. Small mobile crusher can produce tens of tons per hour.Take certain brand mobile crusher with inlet opening 650mm*350mm as an example,assuming that it works 10 hours a day, the daily output can reach 400-500 tons, which exceeds the output of the crushing bucket a little.
The working efficiency of mobile crusher is also restricted by many factors. Material properties are one of the important influencing factors. The hardness, humidity, viscosity and other characteristics of different materials will have different degrees of influence on the crushing efficiency. The configuration and performance of the equipment are also crucial. High-performance crushers, screening machines and reasonable equipment combinations can significantly improve production efficiency. In addition, the production organization and management level on site also have a great impact on the working efficiency of mobile crushers, such as whether the material supply is timely and whether the equipment maintenance is in place.
In large-scale open-pit mining projects, the high-efficiency advantages of mobile crushers are fully demonstrated. A large amount of ore produced by mining needs to be crushed and processed in time. Mobile crushers can operate directly on the mine site, quickly crush large pieces of ore into the required particle size, and then transport the crushed ore to the subsequent processing link through a belt conveyor. Its efficient continuous operation capacity can meet the needs of large-scale production in mines and greatly improve the overall efficiency of mining.
1.3 Summary of the efficiency comparison between the two
Mobile crushers are suitable for rapid crushing of large-scale materials, such as large-scale mining, large-scale building demolition and other projects. The output of the crushing bucket is relatively small, which is more suitable for small construction sites, narrow areas of the site and scenes with little demand for material crushing.
In terms of applicable scenarios, the mobility and flexibility of the crushing bucket give it obvious advantages in urban construction, road maintenance, small building demolition and other operations, and it can operate efficiently in complex and narrow environments. Mobile crushers are more suitable for large open-pit mines, large construction waste treatment sites and other scenes with open sites and large material handling volumes, and can give full play to its characteristics of efficient and continuous operation.
2.Economic Benefit Comparison
2.1 Economic Benefit Analysis of Crushing Bucket
2.1.1 Equipment Purchase Cost
The price of the crushing bucket mainly depends on its model, specification and brand. Generally speaking, the price of a small crushing bucket is more than 100,000 yuan, while the price of a large, high-performance crushing bucket can reach hundreds of thousands of yuan. For example, an ordinary crushing bucket suitable for 10-15 ton excavators has a market price of about 150,000 to 200,000 yuan; while an imported high-end crushing bucket suitable for 30-40 ton large excavators may cost as much as 500,000 to 600,000 yuan. Compared with the purchase cost of millions of mobile crushers, the equipment purchase cost of crushing buckets is relatively low, which is more acceptable to small enterprises or individual operators with limited financial strength.
2.1.2 Operation cost
1) Energy consumption cost: The crushing bucket mainly relies on the hydraulic system of the excavator for power, and its energy consumption is related to the working state of the excavator and the difficulty of material crushing. Generally speaking, the fuel consumption of an excavator equipped with a crushing bucket is about 10-30 liters per hour. Calculated at a diesel price of 7 yuan/liter, the energy consumption cost per hour is about 70-210 yuan. Compared with mobile crushers, due to its relatively small power demand, the energy consumption cost is relatively low.
2)Maintenance cost: The structure of the crushing bucket is relatively simple, and the main wearing parts are jaw plates, hydraulic motors, etc. The service life of the jaw plate usually ranges from 1000 to 3000 hours, depending on the hardness of the material and the frequency of use. The cost of replacing a pair of jaw plates varies depending on the material and brand, and is approximately between 5000 and 20000 yuan. The maintenance of the hydraulic motor is relatively complicated, but as long as the hydraulic oil and filter element are replaced regularly, there are generally fewer failures, and the maintenance cost is about 1000-3000 yuan each time. In general, the maintenance cost of the crushing bucket is relatively low.
2.1.3 Benefits
In some construction waste recycling projects, crushing buckets are used to crush construction waste into recycled aggregates, which can be used to produce recycled bricks, road base materials, etc. Taking the production of recycled bricks as an example, the cost of each ton of recycled aggregate (including equipment depreciation, energy consumption, labor, etc.) is about 50-80 yuan, while the price of recycled bricks on the market is about 200-300 yuan/cubic meter. Calculated based on the consumption of 1.5-2 tons of recycled aggregate per cubic meter of recycled bricks, the profit per ton of recycled aggregate can reach about 70-120 yuan. If an excavator equipped with a crushing bucket produces 200 tons of recycled aggregate per day, the daily profit can reach 14,000-24,000 yuan, with significant economic benefits.
2.2 Economic Benefit Analysis of Mobile Crusher
2.2.1 Equipment Purchase Cost
The equipment purchase cost of mobile crusher is relatively high, and its price varies depending on factors such as the type, configuration, and production capacity of the equipment. The price of a common tire-type mobile crusher is between 1 million and 5 million yuan, while the price of a crawler-type mobile crusher is usually between 2 million and 8 million yuan or even higher due to its stronger mobility and off-road performance. For example, a medium-configuration tire-type mobile crusher with an output of 200-300 tons per hour has a market price of about 2 million to 3 million yuan; while a high-performance crawler-type mobile crusher with an output of more than 500 tons per hour may cost more than 5 million yuan. Such a high purchase cost places high demands on the financial strength of the enterprise.
2.2.2 Operation cost
1. Energy consumption cost: Mobile crushers are usually equipped with high-power motors or engines, which consume a lot of energy. Take a mobile crusher with an output of 300 tons per hour as an example. If it is driven by a motor, its total power can reach 300-500 kilowatts, and the power consumption per hour is about 300-500 degrees. Calculated at the industrial electricity price of 1 yuan/degree, the energy cost per hour is 300-500 yuan; if it is driven by an engine, the fuel consumption per hour is about 50-100 liters. Calculated at the diesel price of 7 yuan/liter, the energy cost per hour is 350-700 yuan. Compared with the crushing bucket, the energy consumption cost of the mobile crusher is significantly higher.
2.2.3 Maintenance cost
Due to the complex structure and the inclusion of multiple equipment components, the maintenance cost of the mobile crusher is relatively high. The hammer head, liner and other wearing parts of the crusher are frequently replaced. The price of a set of hammer heads is tens of thousands of yuan, and the service life is generally 1000-3000 hours; the screen of the screening machine also needs to be replaced regularly, and the price of each screen is several thousand yuan. In addition, the overall maintenance of mobile crushers is relatively complicated and requires professional technicians to operate. The annual maintenance cost can reach hundreds of thousands of yuan.
2.2.4 Revenue
In large-scale mining projects, mobile crushers can quickly crush ore into the required particle size through large-scale and efficient crushing operations, providing raw materials for subsequent mineral processing and other links. Assuming that a mine with a daily output of 10,000 tons of ore uses mobile crushers for crushing, the processing cost per ton of ore (including equipment depreciation, energy consumption, labor, maintenance, etc.) is about 30-50 yuan, while the price of ore that meets the requirements on the market is about 80-120 yuan/ton, and the profit per ton of ore can reach about 30-70 yuan. The daily profit can reach 300,000-700,000 yuan, which is quite considerable in the long run.
2.3 Comparison of the economic benefits of the two
From the perspective of equipment purchase cost, the crushing bucket has obvious advantages, its price is relatively low, and it is more suitable for enterprises or individuals with limited funds. The purchase cost of mobile crushers is high, and the financial strength of enterprises is required to be high. In terms of operating costs, the energy consumption and maintenance costs of the crushing bucket are lower than those of the mobile crusher. The mobile crusher has a higher operating cost due to its high energy consumption and complex maintenance requirements. However, in terms of revenue, although the crushing bucket can achieve certain profits in small projects, the mobile crusher can obtain more lucrative revenue in large projects due to its large-scale production capacity.
Overall, for small projects or operators with limited funds, the crushing bucket has a greater advantage in economic benefits and can achieve better returns with lower cost investment. For large projects, although the purchase and operation costs of the mobile crusher are high, it still has irreplaceable advantages due to the high returns brought by its large-scale production.
3.Conclusion
Through a detailed comparative analysis of the efficiency and economic benefits of the crushing bucket and the mobile crusher, we can clearly see that the two equipment have their own advantages and disadvantages. In terms of efficiency, the mobile crusher has a large crushing capacity and is suitable for large-scale material crushing scenarios; the crushing bucket performs well in small construction sites and narrow venues with its mobility and flexibility. In terms of economic benefits, the purchase cost of crushing bucket equipment is low, and the operating cost is relatively low, so it can achieve good returns in small projects; although the purchase and operating costs of mobile crushing are high, it can obtain lucrative profits in large projects by virtue of large-scale production.
Therefore, in practical applications, enterprises and practitioners should choose appropriate crushing equipment after comprehensive consideration based on specific project requirements, site conditions, financial conditions and other factors. For small-scale building demolition, road maintenance and other projects, crushing bucket is a more ideal choice; while for large-scale projects such as large-scale mining and large-scale construction waste treatment, mobile crushing can better play its advantages. Only by selecting equipment reasonably can we maximize economic benefits while improving production efficiency.
