Fixed jaw crushers for iron ore crushing

Global Case Studies: Fixed Jaw Crushers in Action

1. Australian Mining Co. Enhances Iron Ore Output

At a major iron ore site in Western Australia, a fixed jaw crusher model PE-400×600 processes over 350 tons of raw ore hourly. Its deep crushing chamber and high reduction ratio (4–6:1) ensure uniform particle sizes, critical for downstream smelting processes. The stationary jaw plates, made from manganese steel, withstand abrasive ore conditions, reducing replacement frequency by 40% compared to traditional designs.

2. Canadian Ore Processing Plant Adopts PEX Series

A Quebec-based facility uses the PEW-250×1200 fixed jaw crusher for secondary crushing. With adjustable discharge settings (25–60 mm), it refines coarse iron ore into precise sizes for pelletizing. The electric drive system cuts energy consumption by 15%, aligning with the plant’s sustainability goals.

How Fixed Jaw Crushers Work for Iron Ore

Key Components and Crushing Mechanism

• Fixed Jaw Plate: The stationary component against which ore is compressed.
• Movable Jaw Plate: Driven by an eccentric shaft, it creates a reciprocating motion to crush material.
• Toggle Plate: Ensures safe overload protection and efficient power transmission.

The process begins with raw iron ore fed into the chamber. As the movable jaw exerts force, ore is crushed against the fixed plate until it reaches the desired size and exits through the discharge gap.

Advantages of Fixed Jaw Crushers in Ore Processing

1. High Durability: Reinforced frames and wear-resistant plates (e.g., tungsten carbide or manganese steel) extend operational life in abrasive environments.
2. Low Maintenance: Simple design reduces downtime. Routine checks on lubrication and fasteners ensure smooth operation.
3. Energy Efficiency: Advanced motor designs and optimized crushing chambers lower power consumption per ton.

For installations in harsh climates, such as Scandinavian iron mines, these crushers are equipped with anti-freeze lubrication systems to maintain performance at sub-zero temperatures.

Maintenance and Installation Best Practices

Pre-Startup Checklist for Fixed Jaw Crushers

• Lubrication: Ensure toggle plates and bearings are adequately greased.
• Fastener Inspection: Tighten bolts to prevent vibration-induced loosening.
• Crushing Chamber Cleanliness: Remove debris to avoid blockages.

For detailed guidelines, refer to our Jaw Crusher Installation guide.

Energy-Saving Innovations in 2025 Models

Modern energy-saving jaw crushers integrate smart technologies:

• Variable Frequency Drives (VFDs): Adjust motor speed based on feed load, reducing idle power use by 20%.
• Composite Materials: Lightweight yet durable components lower energy demands without compromising strength.

Explore our Energy-Saving Jaw Crushers page for the latest advancements.

2025 Price Trends: Balancing Cost and Performance

A 2025 Jaw Crusher Price Comparison reveals that mid-sized fixed jaw units (e.g., PE-600×900) range from 50,000 to 80,000, depending on automation features and material quality. High-capacity models like the PE-1200×1500 exceed $150,000 but offer 30% higher throughput for large-scale operations.

Fixed jaw crushers remain a cornerstone of iron ore processing, combining reliability with cutting-edge efficiency. Whether optimizing an existing plant or designing a new facility, selecting the right crusher—and maintaining it properly—ensures long-term profitability. For tailored advice, consult our experts or visit our Jaw Crusher resource hub.