Introduction
Investing in an efficient iron ore crushing plant requires a clear understanding of costs, equipment selection, and production capacity. This guide provides a detailed quotation breakdown for a complete 150-500 TPH iron ore crushing plant, covering essential machinery, price factors, and cost-saving tips.
Key Factors Affecting Iron Ore Crushing Plant Cost
- Plant Capacity (TPH)
- Small-scale (50-150 TPH) vs. Large-scale (300-500+ TPH)
- Type of Crushers Used
- Primary Crusher (Jaw/Gyratory)
- Secondary/Tertiary Crushers (Cone/Impact)
- Automation & Control Systems
- Basic manual vs. advanced PLC-controlled plants
- Mobility
- Fixed plant (for long-term projects) vs. Mobile crushers (for flexible operations)
- Additional Components
- Feeders, screens, conveyors, dust suppression, and power supply
Sample Quotation for a 300 TPH Iron Ore Crushing Plant
1. Primary Crushing – Jaw Crusher
- Model: C150 Jaw Crusher
- Input Size: Up to 1,000 mm
- Output Size: 150-250 mm
- Power: 250 kW
- Estimated Price: $250,000 – $350,000
2. Secondary Crushing – Cone Crusher
- Model: HP300 Multi-Cylinder Hydraulic Cone Crusher
- Input Size: 150-250 mm
- Output Size: 30-50 mm
- Power: 315 kW
- Estimated Price: $300,000 – $450,000
3. Tertiary Crushing (Optional) – Vertical Shaft Impact (VSI) Crusher
- Model: Barmac B6150SE
- Input Size: <50 mm
- Output Size: 0-10 mm (for pellet feed)
- Power: 250 kW
- Estimated Price: $200,000 – $300,000
4. Screening System – Vibrating Screens
- Model: 3-deck 2.4m x 6m screen
- Capacity: 300 TPH
- Estimated Price: $80,000 – $120,000
5. Conveyors, Feeders & Dust Control
- Feeders: Apron feeder (~$30,000)
- Conveyor Belts: $50,000 – $100,000
- Dust Suppression System: $15,000 – $50,000
6. Electrical & Control System
- PLC Automation: $50,000 – $100,000
7. Installation & Civil Work
- Foundations, Erection: $100,000 – $200,000
| Total Estimated Cost (300 TPH Plant) | $1,000,000 – $1,700,000 |
|---|
(Prices vary based on location, manufacturer, and customization.)
Mobile vs. Fixed Iron Ore Crushing Plant Costs
| Feature | Mobile Plant | Fixed Plant |
|---|---|---|
| Cost | Higher upfront ($1.2M – $2M) | Lower upfront ($1M – $1.7M) |
| Flexibility | Easy relocation | Permanent setup |
| Maintenance | More frequent | Less frequent |
| Best For | Temporary sites, mining leases | Large-scale, long-term quarries |
How to Reduce Iron Ore Crushing Plant Costs?
Consider used/refurbished equipment (20-40% savings).
Choose modular designs for easier expansion.
Optimize power consumption with energy-efficient crushers.
Plan for maintenance (predictive vs. reactive repairs).
Conclusion
A 300 TPH iron ore crushing plant typically costs $1M – $1.7M, depending on equipment selection and automation level. Key components like jaw crushers, cone crushers, and screens significantly influence pricing. For an exact quotation, consult suppliers like Metso, Sandvik, or Terex, and request a customized proposal based on your ore characteristics and production goals.
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