The CSP Mühendislik Mining Guide is our comprehensive technical resource centre for crushing and screening plants, quarries and mining operations. On this page you will find all our guides grouped by topic: from crushers to screens, conveyors to washing systems, spare parts selection to maintenance planning, and quarry planning to mineral processing.
Each guide covers working principles, selection criteria, maintenance and fault diagnosis, spare parts lists, checklists and frequently asked questions. To find the right spare part for your equipment or to get technical support, you can reach our engineers directly via the WhatsApp line at the end of each guide.
Contents
- Basics: Definitions, Size Charts and Calculations
- Crushers: Equipment Guides
- Screening, Feeding and Material Handling
- Washing and Water Management
- Spare Parts Guides
- Machine Elements and Power Transmission
- Jaw Crusher Components: Maintenance and Replacement
- Cone Crusher Components: Maintenance and Replacement
- Impact and Vertical Shaft (VSI) Crusher Components
- Conveyor Components: Maintenance and Replacement
- Operation, Maintenance and Efficiency
- Mining, Quarry Planning and Mineral Processing
- Aggregates, Plant Set-Up and Sector Applications
Basics: Definitions, Size Charts and Calculations
Crusher, chippings, aggregate and mining basics; bearing, screen wire, belt, conveyor and gearbox size charts and calculation methods; licensing and operator guides.
- What Is a Crusher? Types, How It Works and Selection Guide — What is a stone crusher and what does it do? Jaw, cone, impact, VSI and hammer crusher types, working principle, factors that determine capacity and how to choose the right crusher.
- Crushed Stone Chippings: Types, Sizes and Bulk Density — What are crushed stone chippings (mıcır) and how are they produced? Common size fractions, types by rock, how many tonnes in 1 m³, bulk density, uses and the factors behind chippings prices.
- What Is Aggregate? Types, Properties and Uses — What is aggregate? Natural, crushed, artificial and recycled aggregate, fine and coarse aggregate, bulk density, aggregate properties, aggregate quarries and plants, and main uses.
- What Is Mining? Types of Mines and Mining Methods — What is mining? Open-pit and underground mining, quarries, types of mines, the stages of a mining project, mineral processing and the role of crushing and screening plants in mining.
- Crusher and Crushing Plant Prices: What Determines the Cost? — Factors that determine crusher and crushing and screening plant prices: capacity, crusher type, mobile vs fixed plant, civil works, electrics, operating cost and the information needed for an accurate quote.
- Jaw Crusher Sizes Explained: Feed Opening, Capacity and Selection — What do jaw crusher sizes such as 600×400, 900×600 or 1200×900 mean? Feed opening, maximum feed size, setting range, approximate capacity and motor power table, and how to choose the right size.
- Screen Wire Sizes and Mesh Chart: Aperture, Wire Diameter, Open Area — How to choose screen wire sizes: aperture, wire diameter, mesh calculation and open area chart; square, slotted and self-cleaning screen wire types, hooks and ordering information.
- Aggregate Sieve Analysis and Grading Curve: Test Steps — How is aggregate sieve analysis carried out? Sample preparation, washing, sieve sizes, calculating percentage retained and passing, plotting the grading curve, fines content and a worked example.
- Bearing Numbers and Sizes: What Do ZZ, 2RS and C3 Mean? Size Chart — How to read a bearing number: what 6205 and 22216 mean, ZZ, 2RS, C3 and K suffixes, size charts for 6000, 6200, 6300, 22200 and 22300 series bearings, and how to measure an unmarked bearing.
- Belt and Pulley Calculation: Belt Length, Speed Ratio and Pulley Sizes — How to calculate belt length: pulley diameter and speed ratio, centre distance, belt speed, wrap angle, V-belt profiles and reading belt numbers; a worked belt and pulley calculation.
- Gearbox Calculation: Ratio, Torque, Power and Gear Oil Selection — How to do a gearbox calculation: ratio, output speed and torque, service factor, a conveyor pulley example, thermal capacity and which gear oil grade to use; ISO VG selection table.
- Belt Conveyor Calculation: Capacity, Belt Speed and Motor Power — How to calculate a belt conveyor: capacity by belt width, belt speed selection, incline factor, motor power calculation and a worked example; conveyor types and a design checklist.
- Conveyor Idler Sizes: Roller Diameter, Length and Shaft Size Chart — How are conveyor idler sizes determined? Roller length chart by belt width, standard roller diameters, shaft diameters and spanner flat sizes, bearing types, idler spacing and ordering information.
- How to Open a Quarry in Turkey: Licences, Documents and Permits — How is a quarry opened in Turkey? Mining licence, EIA, operating permit, forestry and other public permits, required documents, technical supervisor, safety obligations and quarry start-up cost items.
- Crusher Operator: Duties, Training and Safety Instructions — What does a crusher operator do? Job description, shift checklist, required training and certification, crushing and screening plant safety instructions and an example risk assessment table.
Crushers: Equipment Guides
Working principles, setting, operation and maintenance of every crusher type, from primary crushing to sand production.
- What Is a Jaw Crusher? Working Principle, Setting, Operation and Maintenance Guide — How does a jaw crusher work, how is the CSS set and when should jaw plates be turned? A complete guide with a daily checklist, maintenance schedule and troubleshooting table.
- What Is a Cone Crusher? Working Principle, Setting, Lubrication and Maintenance Guide — How does a cone crusher work, why do CSS and choke feeding matter, and how are oil temperature and pressure monitored? Maintenance schedule, troubleshooting table and liner change criteria.
- What Is an Impact Crusher? Working Principle, Settings and Maintenance Guide — How does an impact crusher (HSI) work? Rotor speed, front and rear apron setting, blow bar selection and turning time, tertiary impact crushers and a maintenance schedule in one guide.
- Vertical Shaft Impactor (VSI): Working Principle, Sand Production and Maintenance Guide — How does a vertical shaft impactor (VSI) work? Rock-on-rock vs rock-on-anvil, rotor tip speed, cascade feeding, rotor balance and maintenance schedule in a sand production guide.
- Hammer Crusher: Working Principle, Glass and Coal Crushers, Maintenance Guide — How does a hammer crusher work? Grate opening, hammer tip speed, turning hammers and reversing rotation, glass crusher and coal crusher applications, maintenance and troubleshooting.
- Gyratory Crusher: Working Principle, Selection and Maintenance — What is a gyratory crusher and how does it work? Comparison with jaw crushers, spider, mantle and concave maintenance, hydroset, lubrication and spare parts guide.
- Roll Crusher: Working Principle, Types, Setting and Maintenance — How does a roll crusher work? Single and double roll types, reduction ratio, gap setting, roll surface maintenance, the difference from HPGR, and spare parts.
- Mobile Crusher and Mobile Screen Maintenance: Daily Checks and Maintenance Plan — Tracked mobile crusher and mobile screen maintenance: diesel engine, hydraulic system, tracks, conveyors, wear parts, daily checklist, transport, winter conditions and long-term parking.
Screening, Feeding and Material Handling
Vibrating screens, screen media, feeders, hoppers, conveyors and weighing systems.
- Vibrating Screens: Working Principle, Inclined vs Horizontal Screen Selection and Maintenance Guide — What is a vibrating screen and how to choose one? Inclined vs horizontal, screen motors and drive types, screen bearings, wire and panel selection, maintenance and price factors.
- Choosing Screen Media: Wire Mesh, Polyurethane and Rubber Panels — How to choose screen media? Woven wire, self-cleaning wire, polyurethane and rubber screen panels, perforated plate; a comparison of open area, life, tensioning and fixing systems.
- Non-Clogging Screen Wire: Types, Selection, Installation and Applications — What is non-clogging screen wire and how does it work? Slot, triangle and diamond types, selection for wet and clayey material, tensioning, installation, wear and comparison with woven wire.
- Feeder Types: Selecting and Maintaining Vibrating, Grizzly, Wobbler and Apron Feeders — Differences between vibrating grizzly feeders, wobbler feeders and apron feeders; which to choose for which material, capacity adjustment and maintenance schedule.
- Stockpile and Feed Bins: Design, Capacity, Preventing Bridging and Maintenance Guide — How is a stockpile or feed bin designed? Mass flow and funnel flow, preventing bridging and ratholing, wear liners, capacity calculation and a maintenance checklist.
- Belt Conveyors: Components, Belt Tracking, Tensioning and Maintenance Guide — How does a belt conveyor work? Belt tracking adjustment, correct belt tension and sag, idler and pulley lagging checks, belt cleaners and a maintenance schedule.
- Belt Scales: Selection, Installation, Calibration and Maintenance Guide — How does a conveyor belt scale work? Correct installation conditions, zero and span calibration, chain and material tests, sources of error and maintenance tips.
- Magnetic Separators and Metal Detectors: Protecting Crushers from Tramp Metal — Protecting crushers from uncrushable metal with overband magnetic separators, magnetic head pulleys and metal detectors: selection, layout, maintenance and cost guide.
- Aggregate Stockyard Management: Segregation, Contamination and Inventory — How should an aggregate stockyard be managed? Stockpiling methods, radial stacking conveyors, preventing segregation and contamination, drainage, drone inventory surveys and stockpile tunnel safety.
Washing and Water Management
Sand washing, fine sand recovery, dewatering and pond-free operation.
- Screw Sand Washer: Working Principle, Selection, Water Use and Maintenance Guide — How does a screw sand washer work? Fine and coarse material washers, rising current water, weir setting, flight and shoe wear, greasing and efficient water use.
- Hydrocyclones: Working Principle, Cut Size Adjustment and Maintenance — How does a hydrocyclone work? Cut size, feed pressure, vortex finder and apex setting, spray and roping discharge, sand recovery, liner wear and a maintenance guide.
- Dewatering Screen: Selection, Panels and Maintenance — What is a dewatering screen and how does it work? Reducing sand moisture, polyurethane slotted panels, sand recovery with hydrocyclones, vibrator motors and a maintenance guide.
- Thickeners and Filter Presses: Water Recovery in Washing Plants — How is water recovered in a washing plant with a thickener and filter press? Flocculant selection, sludge management, filter cloth maintenance and pond-free operation.
Spare Parts Guides
Selection, materials, replacement and stock planning for crusher, screen and conveyor spare parts, including crusher backing compounds.
- Crusher Spare Parts: A Selection Guide — Crusher spare parts guide: jaw, cone, impact and vertical shaft crusher parts, wear and mechanical parts, material selection, stock planning and quick quotes.
- Jaw Crusher Spare Parts: Parts List and Selection Guide — What are the parts of a jaw crusher? Jaw plates, cheek plates, toggle plate, pitman, eccentric shaft, bearings, flywheel and tension springs: a selection, replacement and stock guide.
- Cone Crushers Spare Parts — Cone crushers are an important equipment used especially in mining, construction and industrial sectors. In order for this equipment to work in…
- Impact Crusher Spare Parts: Comprehensive Guide and Selection Criteria for Mining Machinery — Impact Crusher Spare Parts: Comprehensive Guide and Selection Criteria for Mining MachineryImpact crusher spare parts play a critical role among mining machines…
- Vertical Shaft Impact Crusher Spare Parts: A Guide to Maintenance and Replacement — Introduction Vertical shaft impact (VSI) crushers are widely used in the mining and aggregate industries for crushing materials such as rock, gravel,…
- Vibrating Screen Spare Parts: Screen Wire, Panels, Bearings, Springs — What are the spare parts of a vibrating screen? Screen wire and panels, tensioning rails, eccentric shaft and bearings, springs, vibrating motors, belts and liners: a selection and stock guide.
- Conveyor Spare Parts: Belt, Idler, Pulley and Scraper Guide — What are conveyor spare parts? A guide to conveyor belts, carrying and return idlers, drive and tail pulleys, scrapers, skirt rubber, take-ups, impact bars and safety equipment.
- Wholesale Crushing Screening Plant Spare Parts: Comprehensive Guide for Mining Machinery — Wholesale Crushing Screening Plant Spare Parts: Comprehensive Guide for Mining MachineryIn this comprehensive guide prepared for mining sector professionals seeking wholesale crushing…
- Cone Crusher Mantle and Concave Replacement: Step-by-Step Guide — When and how are the mantle and concave (bowl liner) of a cone crusher replaced? Wear measurement, removal, seating surface checks, backing pour, first start-up and common mistakes.
- Crusher Backing Compound for Cone and Gyratory Crushers (Aurox and Nordbak): Application Guide — Backing compound for cone and gyratory crushers: what it does, Aurox and Nordbak backing, quantity, mixing, pouring temperature, cure time and common mistakes.
- Aurox Backing Compound: Crusher Liner Backing Guide — What is Aurox backing compound? Supporting mantles and concaves in cone and gyratory crushers: key properties, application steps, product selection and frequently asked questions.
- Aurox Eccentric Liquid Wedge (Locking Compound): Securing Cone Crusher Bushings — What is Aurox eccentric liquid wedge (locking compound) and how is it applied? Securing cone crusher eccentric bushings with a three-component epoxy, advantages over zinc and application steps.
- Securing the Eccentric Bushing: Zinc Pouring or Epoxy Liquid Wedge? — How is a cone crusher eccentric bushing secured? Zinc pouring vs epoxy liquid wedge (Aurox, Nordbak): safety, application, heat, removal and cost compared.
- How Much Crusher Backing Compound Do You Need? Quantity Calculation Guide — How many kits of backing compound does a cone or gyratory crusher need? Gap volume calculation, weight and kit count, safety margin, record keeping and a practical guide for Aurox backing.
- Applying Crusher Backing Compound in Cold Weather — How is backing compound applied to a cone crusher in winter? Warming material and parts, enclosures and heaters, mixing, pouring, cure monitoring and cold-climate application with Aurox.
- Crusher Backing Compound Problems: Loose Liners, Soft Backing and Solutions — Backing compound problems in cone crushers: loose mantles, cracked concaves, soft or porous backing. Symptoms, root causes and lasting solutions in one troubleshooting guide.
- Crusher Wear Parts: Manganese, Martensitic, Chrome and Ceramic — How to choose crusher wear parts? Mn13, Mn18, Mn22 manganese steel, martensitic steel, high chrome, ceramic-reinforced parts, wear plates and extending wear life.
- What Is a Wear Plate? Types, Hardness Grades and Uses — What is a wear plate? 400, 450 and 500 HB wear steels, chromium carbide overlay plates, ceramic and rubber liners; bin, chute, crusher and bucket applications, cutting and welding.
Machine Elements and Power Transmission
Bearings, bushings, belts, shafts, gears, springs, seals and fasteners used in mining machinery.
- What Is a Bearing? Types, Selection, Mounting and Failure Analysis — What is a rolling bearing and what types are there? Bearing selection for crushers, screens and conveyors, bearing housings, mounting, greasing, failure modes and a spare bearing guide.
- What Is a Shaft Bushing? Bushing Types, Materials and Replacement — What is a shaft bushing and what does it do? Plain bearing bushings, bronze and polymer bushings, taper lock bushes, shaft repair sleeves, eccentric bushings, fitting, lubrication and replacement.
- What Is a Belt? Belt Types, V-Belt Selection and Tensioning — What is a drive belt? V-belt, narrow wedge, timing, poly-V and flat belt types; pulley selection, belt tension, alignment, failures and a guide to crusher and screen belts.
- What Is a Drive Shaft and What Does It Do? Types, Torque and Failures — What is a drive shaft and what does it do? Drive shaft torque calculation, cardan and CV shafts, dust boots, shaft materials, failure symptoms and drive shafts in mining machinery.
- What Is a Crown Wheel and Pinion? Bevel Gears and Types of Gears — What is a crown wheel and pinion and what does it do? Bevel and hypoid gears, spur, helical, planetary and worm gear types, gear materials, adjustment, lubrication and gears in mining machinery.
- What Is a Gearbox? Types, Lubrication, Maintenance and Fault Diagnosis — What is a gearbox (speed reducer) and what does it do? Helical, bevel-helical, planetary and worm gearboxes, oil selection, alignment, backstops, maintenance and fault diagnosis.
- Types of Spring and Their Properties: A Guide to Crusher and Screen Springs — What types of spring are there? Compression, extension, torsion, disc and leaf springs; spring materials, spring rate, jaw crusher tension springs, cone crusher springs and vibrating screen springs.
- Types of Hydraulic Seals: U-Cup Seals, T-Seals and Wiper Seals — What types of hydraulic seals are there? U-cup seals, T-seals, piston and rod seals, wiper seals, O-rings, guide strips; materials (NBR, PU, FKM, PTFE), selection, fitting and failures.
- What Is a Bolt? Types of Bolts and Nuts, Property Classes — What is a bolt and what is a nut? Bolt types, 8.8, 10.9 and 12.9 property classes, nut types, tightening torque, crusher wear part bolts, preventing loosening and mining applications.
- What Is a Locking Compound and How Does It Work? — What is a locking compound (liquid threadlocker) and how does it work? Anaerobic cure, low-medium-high strength, application steps, removal, bolt and nut locking and use in mining.
- Pump Parts: Slurry Pump and Oil Pump Spare Parts — What are pump parts? Centrifugal slurry pump impellers, casing liners, throat bushes, gland packing and mechanical seals; what an oil pump does, failure symptoms and a maintenance guide.
Jaw Crusher Components: Maintenance and Replacement
Detailed maintenance, failure and replacement guides for every jaw crusher part.
- Jaw Crusher Jaw Plates: Maintenance and Replacement — Jaw crusher jaw plates: function, wear signs, inspection, maintenance, step-by-step replacement and turning, and what to check when buying spare jaw plates.
- Jaw Crusher Cheek Plates: Wear, Replacement and Selection — What do jaw crusher cheek plates do and when should they be replaced? Wear limits, replacement steps, material selection and how to protect the crusher frame.
- Jaw Crusher Toggle Plate and Toggle Seats Guide — Jaw crusher toggle plate and toggle seats: function, failure signs, maintenance, replacement steps and how to choose the right spare parts.
- Jaw Crusher Pitman: Maintenance and Failure Guide — Jaw crusher pitman: function, design, failure signs, inspection, maintenance, repair, replacement and the critical points when choosing spare parts.
- Jaw Crusher Eccentric Shaft and Bearings Maintenance — Jaw crusher eccentric shaft and bearings: function, failure signs, measurement, greasing, replacement steps and safe maintenance recommendations.
- Jaw Crusher Flywheel: Function, Maintenance and Replacement — What is a jaw crusher flywheel and what does it do? Wear and failure symptoms, inspection, maintenance, replacement steps, LOTO and spare part selection guide.
- Jaw Crusher Tension Rods and Springs: Maintenance and Replacement — What do jaw crusher tension rods and springs do, how are they adjusted and when are they replaced? Hydraulic tensioning, failure signs, maintenance schedule and spare parts.
- Jaw Crusher CSS Setting System: Shims, Wedges and Hydraulic Adjustment — How is the CSS of a jaw crusher measured and adjusted? Shim, wedge and hydraulic setting systems, maintenance of setting parts, failure signs and spare part selection.
- Jaw Crusher Main Frame: Maintenance and Repair — What is the jaw crusher main frame, how is it inspected, what failures occur and how are repair and replacement carried out? A technical maintenance guide.
Cone Crusher Components: Maintenance and Replacement
Main shaft, eccentric, bushings, gears, hydraulic and lubrication systems.
- Cone Crusher Main Shaft and Head Assembly: Maintenance and Repair — What do the cone crusher main shaft, head and head nut do and how are they inspected and repaired? Failure signs, measurement, overhaul steps and spare parts.
- Cone Crusher Eccentric and Eccentric Bushing Maintenance — Cone crusher eccentric and eccentric bushing: function, failure signs, clearance measurement, maintenance, replacement, LOTO and choosing spare parts.
- Cone Crusher Countershaft, Pinion and Gear: Maintenance and Replacement — How to inspect a cone crusher countershaft, countershaft bushings, pinion and gear: tooth contact, backlash setting, failure signs, replacement and spare parts.
- Cone Crusher Spherical Bearing and Socket Liner: Maintenance — What do the cone crusher spherical bearing (head ball) and socket liner do? Lubrication, wear signs, head spin, inspection, replacement steps and spare parts.
- Cone Crusher Hydraulic Cylinders: Tramp Release, Hydroset and Maintenance — How do cone crusher tramp release cylinders, hydroset cylinders and accumulators work? Seal replacement, precharge pressure, failure signs, maintenance and spare parts.
- Crusher Lubrication Unit: Pump, Filter, Cooler and Oil Maintenance — How does a cone crusher lubrication unit work? Lubrication pump, oil filter, cooler, tank heater, oil analysis, failure signs, maintenance schedule and spare parts.
- Cone Crusher Dust Seal and Dust Collar: Maintenance and Replacement — What do the cone crusher dust seal and dust collar do? Effect of dust ingress on oil and bushings, wear signs, replacement steps and spare part selection.
- Cone Crusher Feed Plate and Distributor: Function, Wear and Replacement — Why are the cone crusher feed plate and distributor important? Even feeding, wear signs, replacement steps, feed box arrangement and spare part selection.
Impact and Vertical Shaft (VSI) Crusher Components
Rotors, blow bars, aprons, liners and VSI wear parts.
- What Is a Rotor? Impact Crusher Rotor: Design, Balancing and Maintenance — What is an impact crusher rotor and what does it do? Rotor types, balancing, wear protection, blow bar slots, failure signs, overhaul and rotor spare parts guide.
- Blow Bars for Impact Crushers: Material Selection, Turning and Replacement Guide — How to choose impact crusher blow bars? Manganese, martensitic, chrome and ceramic blow bar comparison, wear patterns, turning, replacement steps and stock planning.
- Impact Crusher Aprons and Apron Liners: Setting, Wear and Replacement — How are impact crusher front and rear aprons and apron liners set and replaced? The 2:1 gap rule, apron chatter, wear signs and spare part selection.
- Crusher Housing Liners and Side Liners: Selection, Wear and Replacement — What do housing liners and side liners do in impact and other crushers? Material selection, wear tracking, replacement steps, bolt and fitting tips, spare part selection.
- Impact Crusher Apron Adjustment Rods, Springs and Hydraulic Setting System — How does the impact crusher apron adjustment mechanism work? Adjustment rods, spring packs, hydraulic cylinders, overload protection, failure signs, maintenance and spare parts.
- Impact Crusher Main Shaft and Rotor Bearings: Maintenance and Replacement — How to maintain impact crusher main shaft and rotor bearings? Greasing, temperature and vibration monitoring, bearing failures, replacement steps, alignment and spare part selection.
- VSI Rotor Tips: Replacement, Balancing and Wear Life Guide — When should VSI crusher rotor tips and tip protectors be replaced? Tungsten carbide tips, the pair replacement rule, balancing, effect of rotor speed and spare part selection.
- VSI Rotor Cavity Wear Plates and Table Liners: Maintenance Guide — How are VSI crusher rotor cavity wear plates, upper/lower table liners and the rock shelf protected? Wear signs, inspection, replacement steps and spare part selection.
- VSI Distributor Plate: Wear, Replacement and Selection — What does the VSI crusher distributor plate do? Protecting the rotor base, wear signs, inspection frequency, replacement steps, materials and spare part selection.
- VSI Feed Tube and Feed Eye Ring: Alignment, Wear and Replacement — What do the VSI crusher feed tube and feed eye ring do? Alignment, wear signs, replacement steps, feed arrangement and spare part selection.
- VSI Anvil Ring and Rock Shelf: Selection, Wear and Replacement — What are the VSI crusher anvil ring and rock shelf? Rock-on-metal and rock-on-rock modes, anvil wear, rotating segments, replacement steps and spare part selection.
- VSI Bearing Cartridge: Lubrication, Monitoring and Replacement — How does a VSI crusher bearing cartridge work and how is it maintained? Oil level and temperature, vibration, cartridge replacement, overhaul, common mistakes and spare parts.
- VSI Lid Seal and Dust Sealing: Inspection and Replacement — Why is the VSI crusher lid seal important? Dust escape, bearing cartridge protection, seal materials, inspection, replacement steps and spare part selection.
Conveyor Components: Maintenance and Replacement
Belt, idlers, pulleys, take-ups, scrapers, skirt rubber and safety equipment.
- Conveyor Belt: Selection, Splicing, Repair and Replacement Guide — How to choose a conveyor belt? EP and steel cord belts, cover grades, thickness, splicing methods, damage types, repair, replacement and what to check when buying.
- Conveyor Idlers: Carrying, Return and Impact Idlers Guide — How to select conveyor idlers and when to replace them? Carrying (troughing), return and impact idlers, idler frames, the risk of seized rollers, inspection and spare part selection.
- Conveyor Pulley: Drive Pulley, Lagging and Gear Reducer Maintenance — What is a conveyor pulley and how is a drive pulley selected and maintained? Pulley lagging (rubber/ceramic), bearings, motor-gearbox, belt slip problems and spare parts.
- Conveyor Tail and Snub Pulleys: Function, Maintenance and Replacement — How are conveyor tail, snub and bend pulleys maintained? Material build-up, wing pulleys, the link with mistracking, bearing maintenance and spare part selection.
- Conveyor Take-Up: Screw, Gravity and Hydraulic Take-Ups — How to choose and adjust a conveyor belt take-up? Screw, gravity and hydraulic take-ups, correct sag, the harm of over-tensioning, maintenance and spare part selection.
- Conveyor Belt Scrapers: Choosing Primary and Secondary Belt Cleaners — How to choose and adjust a conveyor belt scraper (belt cleaner)? Primary and secondary scrapers, blade materials, contact pressure, V-plough scrapers, maintenance and spare parts.
- Conveyor Skirt Rubber and Loading Chute: Spillage and Dust Control — How to choose and adjust conveyor skirt rubber and the loading chute? Spillage and dust control, impact beds, wear signs, replacement and spare part selection.
- Conveyor Safety Equipment: Pull Cord, Belt Misalignment and Speed Switches — What safety equipment does a belt conveyor need? Emergency stop pull cord switches, belt misalignment switches, speed/slip sensors, rip detectors, guards, testing and spare parts.
Operation, Maintenance and Efficiency
Predictive maintenance, energy efficiency, automation, hydraulic and electrical systems, occupational safety.
- Predictive Maintenance in Crushing and Screening Plants: Seeing Failures Coming with Vibration, Oil Analysis and Sensors — How to set up predictive maintenance for crushers and screens? Vibration monitoring, oil analysis, thermography, power and CSS tracking, threshold values and a step-by-step plan.
- Energy Efficiency in Crushing and Screening Plants: How to Reduce kWh/ton — Ways to reduce energy consumption in crushing and screening plants: blast optimisation, choke feeding, scalping, the right CSS, frequency inverters, electrification and kWh/ton tracking.
- Automation, Remote Monitoring and Digital Twins in Crushing and Screening Plants — How is a smart crushing and screening plant built? Automatic feed and CSS control, SCADA, remote monitoring, AI-assisted optimisation, digital twins and a step-by-step digitalisation roadmap.
- Hydraulic System Maintenance: Pumps, Motors, Cylinders and Oil Cleanliness — Hydraulic system maintenance on crushers and mobile equipment: hydraulic pumps and motors, cylinders, accumulators, oil cleanliness (ISO 4406), filters, hoses and fault diagnosis.
- Electric Motors in Crushing and Screening Plants: Selection and Maintenance — Choosing electric motors for mining and crushing and screening plants: efficiency classes (IE2, IE3, IE4), IP protection, starting methods, inverters, motor protection and maintenance.
- Occupational Safety in Quarries and Crushing and Screening Plants — Safety in quarries and crushing and screening plants: conveyor and crusher entrapment risks, LOTO lockout-tagout, traffic, silica dust, noise and confined space precautions.
- Dust and Noise Control in Crushing and Screening Plants: Technical Solutions — How can dust and noise be reduced in crushing and screening plants? Water sprays and misting, enclosed transfer points, pulse-jet filters, rubber screen panels, layout and measurement.
Mining, Quarry Planning and Mineral Processing
Mining processes from quarry planning and blasting to grinding and critical minerals.
- Quarry Planning: Reserves, Bench Design and Production Planning — How is a quarry planned? Geological survey, reserve estimation, bench height and slope angle, haul road design, crushing plant location, permits, EIA and restoration.
- Rock Crushability: Strength, Abrasiveness and Crusher Selection — How do rock properties affect crusher selection? Compressive strength, Los Angeles abrasion, Bond work index, abrasiveness, silica content and a crusher guide by rock type.
- Drill and Blast Design and Its Effect on Crushing Costs — How is drill and blast design done in a quarry? Hole diameter, burden, spacing, stemming, delay timing, powder factor and the effect of fragmentation on crusher capacity.
- Loading and Haulage in Quarries and Mines: Excavators, Trucks and Conveyors — How can loading and haulage costs be reduced in quarries and mines? Excavator and loader selection, truck matching, cycle time, haul road maintenance, in-pit crushing and conveying.
- What Is Mineral Processing? Crushing, Grinding and Beneficiation — What is mineral processing? Size reduction, classification, liberation, gravity, magnetic separation, flotation, leaching, dewatering and tailings management: a comprehensive guide.
- Ball Mills: Working Principle, Liners, Ball Charge and Maintenance — How does a ball mill work? Critical speed, ball charge and ball size, Bond work index, closed-circuit grinding, mill liner selection, maintenance and spare parts guide.
- SAG and AG Mills: A Guide to Autogenous and Semi-Autogenous Grinding — What are SAG and AG mills? Autogenous and semi-autogenous grinding principles, the SABC circuit, pebble crushers, critical size, control strategy, and liner and grate maintenance.
- Critical Minerals: Lithium, Copper and Rare Earth Elements — What are critical minerals? Lithium, copper, nickel, cobalt, graphite and rare earth elements in the energy transition; boron and REE in Turkey, and new mineral processing technologies.
- Sustainability in Mining: Water, Energy, Waste and Restoration — What is sustainable mining? Water recovery, energy efficiency, carbon footprint, dust and noise, waste management, restoration and ESG for quarries and mineral processing plants.
Aggregates, Plant Set-Up and Sector Applications
Aggregate quality and standards, manufactured sand, sand and gravel, cement–lime and recycling applications.
- What Is a Crushing and Screening Plant and How Is It Set Up? Flowsheet Guide — What is a crushing and screening plant, how does it work and how is it set up? Example flowsheet, capacity calculation, crusher and screen selection, layout, permits and commissioning.
- Mobile Crusher or Stationary Plant? Choosing a Crushing and Screening Plant — What is a mobile crusher and how does it work? Mobile, modular and stationary crushing plants compared: investment and operating cost, capacity, transport and maintenance.
- Aggregate Standards Guide: Concrete, Asphalt, Roads and Ballast — What are the aggregate standards? EN 12620 concrete aggregates, EN 13043 asphalt, EN 13242 roads, EN 13450 ballast; grading, fines, flakiness, LA categories and factory production control.
- Aggregate Quality: Particle Shape, Flakiness Index and the Effect of Crusher Selection — Why does particle shape matter in concrete and asphalt aggregate? Flakiness index, shape index, fines and the Los Angeles test; improving quality through crusher selection and settings.
- Manufactured Sand Production: How to Produce Quality M-Sand as an Alternative to River Sand — What is manufactured sand and how is it produced? How many kg in 1 m³, difference from river sand, rock selection, VSI and cone crushers, screening, filler control and quality.
- Sand and Gravel Pit and River Material Processing Plant Guide — How is a sand and gravel pit operated? Alluvial deposits, screening and washing plants, crushing oversize gravel, clay removal, water management, environmental permits and restoration.
- Crushing and Screening Applications in the Cement and Lime Industry — Crushing limestone, clay and marl in cement and lime plants: hammer and impact crushers, pre-blending stockpiles, size requirements for lime kilns, washing and wear.
- Recycling Construction and Demolition Waste: Recycled Aggregate by Crushing and Screening — How is recycled aggregate produced from concrete, asphalt and demolition waste? Pre-sorting, steel separation, crusher and screen selection, quality control, applications and safety.
Spare Parts and Service
You can find wear and mechanical spare parts for all the equipment covered in these guides on our spare parts page, our maintenance and repair services on our service, maintenance and repair page, crusher backing compounds including our own Aurox brand on our crusher backing page, and our range on our products page. Follow our blog for news and announcements.