In the competitive world of global mining operations, reducing energy consumption while maintaining throughput is no longer optional—it’s essential. Our recent work on a copper mine project in Zambia shows how smart integration of PE jaw crushers and impact crushers can slash unit energy costs by up to 22%, improve product consistency, and meet strict environmental standards—all without compromising production volume.
At this African site, raw ore entered the plant with inconsistent sizes—some pieces over 1 meter long. Without proper pre-screening and staged crushing, the downstream processing suffered from frequent blockages, high wear rates, and excessive power draw. Initial tests showed that using only a single-stage crusher led to a 35% higher kWh/ton compared to optimized multi-stage setups.
| Crushing Stage | Avg. Input Size (mm) | Energy Use per Ton (kWh) | Key Outcome |
|---|---|---|---|
| Single-stage jaw | 0–1020 | 18.7 | High vibration, low efficiency |
| PE Jaw + Impact Crusher | 0–300 → 300–1020 | 14.5 | Stable output, reduced dust, lower maintenance |
By splitting the process into two stages—coarse crushing with a PE jaw crusher followed by medium crushing with an impact breaker—we achieved:
We’ve served over 137 countries in mining, and this exact configuration has been successfully deployed in projects across South America, Southeast Asia, and Africa—with consistent results in both small-scale operations and large industrial plants.
What makes our approach different? It’s not just about selling equipment—it’s about delivering a proven, replicable system tailored to real-world conditions. Whether you're planning a new mine or optimizing an existing one, understanding how each piece interacts matters more than any single machine.
Ready to reduce your energy costs and boost recovery rates?
Get Your Free Crusher Process Optimization Checklist
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