MINERAL PROCESSING SOLUTION
Stable Fixed Crushing Circuits for Hard Rock Mines
SUNREX focuses on the front-end crushing section of mineral processing: fixed jaw and cone circuits built for stable throughput, durable structures, wear-resistant parts, and timely spare support in long-hour mine duty.
Fixed crushing lines are more common in mining
Stable throughput for long-hour operation
Durable wear parts and crusher structure
Timely spare-parts supply support
ORE TYPES
Ore Crushing Applications
For most mine projects, the crushing section is expected to run continuously, hand off a stable mm-level product to grinding or separation, and keep downtime under control through durable wear parts and dependable spare-parts support.
Gold Ore
Jaw + cone crushing is commonly used ahead of grinding, gravity concentration, or flotation. The focus is stable mill feed, steady capacity, and clean transfer to the downstream section.
Copper Ore
Porphyry and chalcopyrite projects usually require steady jaw opening, cone reduction, and precise screening before flotation. Stable tonnage matters more than short-term peak output.
Iron Ore
Hematite and magnetite lines often combine jaw crushing, cone crushing, and screening before magnetic separation or grinding. Equipment durability is critical under abrasive ore duty.
Lead, Zinc & Polymetallic Ores
Mixed-sulfide ore projects need controlled reduction and stable discharge size so downstream flotation receives a consistent feed rather than fluctuating coarse material.
Tin & Tungsten
These dense ores usually require jaw + cone reduction with narrow screening control before gravity or magnetic separation. Stable sizing and low unnecessary fines are both important.
Custom Ores
Rare earths, industrial minerals, phosphates, and other custom ores can be matched with fixed jaw + cone layouts, screen sizing, and conveyor transfer built around the required downstream process.
PROCESSING CIRCUIT
Typical Ore Crushing and Handover Process
In mining projects, the crushing section is usually a fixed layout connected to stockpiles, conveyors, and grinding or separation equipment. The goal of this section is stable mm-level discharge, reliable long-hour duty, and smooth handover to the downstream process β not micron-scale liberation by the crusher alone.
01
Receiving hopper & vibrating feeder
Truck-dumped ore is buffered in the hopper, then fed steadily into the primary crusher. A properly matched feeder helps keep tonnage stable, protects the crusher chamber, and reduces avoidable wear from surge loading.
02
Primary jaw crusher
The jaw crusher opens the run-of-mine feed and creates the first controlled reduction stage. For hard and abrasive ores, this is the normal front-end machine because it is robust, proven, and easy to maintain in continuous mine duty.
03
Secondary / tertiary cone crushing
Single-cylinder, multi-cylinder, or Symons cone crushers are selected according to ore hardness, feed size, target discharge, and capacity. For hard rock ore, cone crushing is generally preferred over impact crushing because wear cost and duty stability are better controlled.
04
Multi-deck screening & recirculation
The vibrating screen classifies the product and returns oversize to the cone stage when tighter size control is required. This is how the crushing line keeps product size in the practical mill-feed range such as 0β20 mm, 0β25 mm, or 0β40 mm.
05
Conveying, stockpile, and downstream transfer
Transfer conveyors, stockpile or buffer arrangements, and electrical control link the crushing line to grinding, gravity separation, flotation, or magnetic separation. The crushing section is successful when the downstream process receives a steady, correctly sized feed.
Why fixed crushing lines are more common
- Mining projects usually run one ore body for years rather than relocating equipment frequently.
- Fixed layouts connect more naturally with stockpiles, long conveyors, grinding mills, and plant utilities.
- They provide easier maintenance access and steadier throughput under long-hour operating conditions.
What customers usually care about most
- Stable throughput instead of short-term peak capacity claims.
- Durable crusher structure and wear-part metallurgy for abrasive ore duty.
- Timely supply of mantles, concaves, jaw plates, and other critical spare parts.
- Discharge size controlled at the mm level before the ore enters grinding or separation.
CIRCUIT CONFIGURATIONS
Recommended Plant Configurations
The recommendations below stay focused on the front-end ore crushing section. For hard and abrasive mining duty, SUNREX normally recommends jaw + cone routes rather than impact crushers. The crushing line typically delivers mm-level mill feed, while finer micron-scale liberation is completed later by grinding mills.
| Ore Type | Throughput | Recommended Equipment & Models | Crushing Route | Typical Discharge Size |
|---|---|---|---|---|
| Gold (Hard Rock) | 80β120 t/h | GF0936 feeder + PE600Γ900 jaw or C106 jaw + single-cylinder cone + 3YK1860 screen + transfer conveyors | Jaw + Single-cylinder Cone | 0β20 mm |
| Copper (Porphyry) | 100β180 t/h | GF1245 feeder + PE750Γ1060 jaw or C106 jaw + HP300 multi-cylinder cone + 3YK2160 screen + stockpile conveyors | Jaw + Multi-cylinder Cone | 0β25 mm |
| Iron Ore | 150β250 t/h | GF1245 feeder + C106 / C116 jaw + Symons cone + heavy-duty vibrating screen + transfer conveyors | Jaw + Symons Cone | 0β25 mm |
| Polymetallic / Hard Abrasive Ore | 200β300 t/h | Heavy-duty feeder + C116 jaw + single-cylinder cone + HP300 / HP400 multi-cylinder cone + 3-deck screen + recirculation conveyors | Jaw + Single-cylinder Cone + Multi-cylinder Cone | 0β20 mm |
COMMON QUESTIONS
Frequently Asked Questions
Below are the questions we hear most often from mine operators, project engineers, and procurement teams evaluating jaw + cone crushing circuits for hard rock ore.
What ores can SUNREX crushing lines handle?
SUNREX crushing lines are designed for gold ore, copper ore, iron ore, tin, tungsten, and other hard rock or polymetallic ores. The mainstream layout is jaw crushing followed by cone crushing, with screening before the material goes downstream to grinding or separation.
Why are fixed crushing lines more common in mining projects?
Most mining projects operate one ore body for years and connect crushing with stockpiles, conveyors, and grinding mills. In that model, a fixed crushing line is usually more practical because it offers steadier throughput, easier maintenance access, and better integration with the downstream process.
Do you recommend impact crushers for hard rock ore?
Usually no. For most hard and abrasive ores, SUNREX recommends jaw crushers with single-cylinder, multi-cylinder, or Symons cone crushers rather than impact crushers, because this route is more suitable for continuous-duty mine crushing circuits.
What product size can the crushing line deliver before grinding?
The crushing section typically delivers mill feed in the millimetre range, such as 0β20 mm, 0β25 mm, or 0β40 mm. Micron-scale liberation is achieved later in downstream grinding mills, not by the crushing line alone.
How do you choose between single-cylinder, multi-cylinder, and Symons cone crushers?
Single-cylinder cones suit secondary crushing and large reduction ratios, multi-cylinder cones suit fine crushing and higher capacity, and Symons cones remain practical for stable medium-fine circuits and cost-sensitive projects. The final choice depends on ore hardness, feed size, target discharge, and throughput.
How do wear parts and spare parts support affect uptime?
Stable mine production depends on the right wear-part metallurgy, predictable replacement cycles, and timely spare supply. SUNREX focuses on durable wear-part materials and planned parts support to help customers keep the crushing line running steadily.
Need Custom Mine Crushing Circuit?
Tell us your ore type, feed size, target discharge, and throughput. We will recommend a practical jaw + cone route, wear-parts plan, and spare-parts support package for the front-end crushing section.