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Metal Mining Crushing & Screening Solutions

Hilook delivers high-capacity crushers, screens, and complete plants for iron ore, copper, gold, and bauxite processing. Increase throughput and reduce downtime with equipment engineered for the toughest mining environments.

Overview

Crushing & Screening in Metal Mining: The Backbone of Mineral Processing

Crushing and screening are the first critical steps in liberating valuable minerals from ore. The right circuit design directly impacts downstream recovery, energy consumption, and overall profitability.

STEP 1

Metal Mining Crushing & Screening Solutions

In metal mining, comminution—crushing and grinding—accounts for up to 50% of total processing energy. Crushing and screening circuits prepare run-of-mine ore for grinding and separation by reducing particle size and classifying material. Whether you process hard rock, abrasive ores, or sticky clays, the configuration of primary, secondary, and tertiary crushing stages, combined with efficient screening, determines your plant's capacity and product quality.

STEP 2

Hilook Solutions for Metal Ore Processing

Hilook's metal mining crushing and screening solutions are engineered to handle the toughest ores, from high-silica gold ore to abrasive copper porphyry. Our equipment portfolio includes jaw crushers for primary reduction, cone crushers for secondary and tertiary crushing, impact crushers for friable materials, and vibrating screens for accurate sizing. We also provide complete crushing and screening plants, mobile and stationary, tailored to your site conditions.

STEP 3

Optimize Mining Plant Performance with Hilook

Primary Crushing: Jaw crushers and gyratory crushers reduce run-of-mine ore from up to 1,500 mm to below 300 mm. Secondary & Tertiary Crushing: Cone crushers and impact crushers further reduce ore to 10–50 mm, preparing it for grinding or heap leaching. Screening: Vibrating screens classify ore into saleable products or feed for the next stage, with high efficiency and minimal blinding. With decades of experience in mineral processing, Hilook helps you optimize your crushing and screening circuit for maximum throughput, lowest cost per ton, and minimal environmental impact.

Challenges

Metal Mining Challenges We Address

Many metal ores impose considerable mechanical and abrasive loads on crushing equipment. If the equipment configuration and wear components do not match the material characteristics, excessive wear can increase maintenance requirements and affect production continuity. We consider factors such as ore hardness, abrasiveness, feed size and required reduction ratio when selecting the appropriate crusher configuration. Jaw crushers can handle large run-of-mine material during primary crushing, while cone crushers are suitable for further size reduction of hard and abrasive materials.

Mining feed material rarely arrives at the crusher with a perfectly uniform size distribution. Large rocks, fines and variations in material flow can affect crusher loading and overall plant stability. A suitable vibrating feeder can regulate the material flow and provide a more consistent feed to the primary crusher. When necessary, pre-screening can also be incorporated to remove natural fines before crushing.

The crushing stage needs to produce material that meets the requirements of the next processing stage. Excessive oversize can increase the load on downstream equipment, while unnecessary over-crushing can increase energy consumption and wear. Our crushing and screening configurations are designed around the required product size, allowing the screening stage to separate qualified material and control the size distribution of the final feed.

Mining operations often run for extended periods under demanding conditions. Equipment downtime can affect multiple stages of production, making reliability and maintenance accessibility important considerations during plant design. We therefore consider not only equipment capacity but also equipment matching, material flow, maintenance access and wear-part requirements when developing a solution.

Core Equipment

Complete Range of Crushers and Screens for Metal Mining

From primary jaw crushers to fine cone crushers and high-frequency screens, Hilook offers a full lineup to match every stage of your ore processing flow.
01

Jaw Crusher for Primary Crushing

CJ Series Jaw Crusher

Our Jaw Crusher provides the primary size-reduction stage for large and irregular run-of-mine ore.
The equipment is designed for heavy-duty applications where the feed material can contain large rocks and hard mineral particles. Its robust crushing structure makes it suitable for integration into fixed metal mining crushing plants.
The jaw crusher can be selected according to the required feed opening, processing capacity and material characteristics.

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02

Cone Crusher for Secondary and Tertiary Crushing

CSC/CHC Series Single-Cylinder Hydraulic Cone Crusher

Our Cone Crusher is used when the material requires further reduction after primary crushing.
Cone crushing is particularly suitable for hard and abrasive ores where the operation requires consistent reduction and controlled product size. Multiple crushing stages can be considered when a finer product is required before grinding or beneficiation.
The final configuration depends on the required throughput, feed size and target product specification.

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03

Vibrating Screen for Particle-Size Control

CLH Series Horizontal Vibrating Screen

Our Vibrating Screen provides classification within the crushing circuit.
Different screen configurations can be selected according to capacity, material characteristics and required separation sizes. Multi-deck screens can also be used when several size fractions need to be separated.
By matching the screen with the crusher capacity, the overall plant can maintain a more balanced material flow and more consistent product size.

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04

Vibrating Feeder for Stable Material Flow

CTK Series Feeders and Prescreens

A Vibrating Feeder controls the rate at which mined ore enters the crushing system.
The feeder helps reduce sudden surges in material flow and supports more stable crusher operation. For projects with significant quantities of natural fines, the feeding section can also be designed to incorporate pre-screening.

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Application
Iron Ore Crushing & Screening

Iron ore is hard and abrasive, requiring wear-resistant liners and robust crushers. Hilook's jaw crushers and cone crushers are configured with high-chrome or manganese steel to withstand the abrasion. Our vibrating screens with polyurethane decks minimize pegging and extend service life. Typical flow: primary jaw crusher, secondary cone crusher, tertiary cone crusher, and double-deck screens for lump and fines separation.
Throughput: up to 2,000 t/h
Product size: 0–10 mm fines, 10–30 mm lumps
Equipment: C Series jaw crusher, HPGR or cone crushers, banana screens

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Application
Copper Ore Crushing & Screening

Copper porphyry ores are typically medium-hard to hard and can be sticky. Our impact crushers and cone crushers offer high reduction ratios, while our screens with high-amplitude vibration handle wet and sticky material. For heap leaching, we provide crushing circuits that produce a uniform 12–25 mm product for optimal leach recovery.
Throughput: 500–3,000 t/h
Product size: 12–25 mm for heap leach, or finer for flotation
Equipment: gyratory or jaw crusher, cone crushers, inclined screens

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Application
Gold Ore Crushing & Screening

Gold ore can vary from soft to very hard, often with high silica content. Hilook's jaw crushers and cone crushers are designed for minimal fines generation and maximum liberation. Our screens with high-frequency vibration efficiently classify fine gold-bearing particles. For small-scale operations, we offer compact mobile crushing and screening plants.
Throughput: 50–1,000 t/h
Product size: 0–10 mm for milling, or 10–20 mm for heap leach
Equipment: jaw crusher, cone crusher, vibrating screen, feeders

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Application
Bauxite Crushing & Screening

Bauxite is relatively soft but can be sticky and high in moisture. Our impact crushers and sizers are ideal for primary and secondary reduction, while our screens with large open area handle wet and sticky feed. We also provide washing screens for bauxite beneficiation.
Throughput: 300–1,500 t/h
Product size: 0–50 mm for alumina refineries
Equipment: impact crusher, sizer, linear motion screens

Process Steps

How to Choose the Right Crushing & Screening Equipment

Selecting the optimal equipment requires careful consideration of ore characteristics, capacity targets, and site conditions. Follow these steps to make an informed decision.
01

Assess Ore Characteristics

Determine hardness (Mohs scale), abrasiveness (Ai), moisture content, and bulk density. These factors dictate crusher type and wear material. For hard, abrasive ore, choose jaw or cone crushers with high-chrome liners. For soft, sticky ore, impact crushers or sizers are better.
02

Define Capacity and Product Size

Calculate required throughput (t/h) based on mine plan. Specify final product size for downstream processes (e.g., 80% passing 12 mm for heap leach). This determines the number of crushing stages and screen area.
03

Evaluate Site Conditions

Consider space availability, mobility requirements, and climate. For remote mines, mobile or semi-mobile plants reduce infrastructure costs. For extreme cold, we offer arctic packages with heated lubrification and special steels.
04

Consider Automation and Maintenance

Automation reduces human error and improves safety. Choose equipment with easy access for maintenance and readily available spare parts. Hilook provides global spare parts network and training.
05

Consult with Experts

Hilook's engineers can perform a site survey and simulation to recommend the optimal circuit. We provide full engineering, procurement, and construction (EPC) services for crushing and screening plants.
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CONTACT US
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    FAQ

    Everything you need to know

    What crushing equipment is commonly used for metal mining?
    Metal mining operations commonly use Jaw Crushers, Cone Crushers and Vibrating Screens as the core equipment in a crushing and screening circuit. A jaw crusher is generally suitable for primary crushing of large run-of-mine ore, while a cone crusher can provide secondary or tertiary size reduction. Vibrating screens classify the crushed material according to the required particle size.
    The final equipment combination depends on the ore type, hardness, feed size, required capacity and target product size.

    How do I choose a crusher for metal ore processing?
    Crusher selection depends on several important factors, including the ore hardness, abrasiveness, maximum feed size, required capacity, reduction ratio and final product size.
    A jaw crusher is commonly considered for primary crushing when the feed contains large rocks. A cone crusher can be used for further reduction when the application requires a smaller and more controlled product size.
    Our engineers can recommend a suitable configuration after evaluating your material and production requirements.

    Why is a vibrating screen important in metal mining?
    A vibrating screen separates crushed ore into different particle-size fractions and helps maintain the required feed size for subsequent processing.
    The screen can send qualified material to the next processing stage while oversize material can return to the appropriate crusher when a closed-circuit configuration is required. This arrangement helps improve particle-size control throughout the crushing circuit.

    What types of metal ores can your crushing equipment process?
    Our crushing and screening equipment can be configured for various hard-rock metal ores, including iron ore, copper ore, gold ore, lead-zinc ore and polymetallic ores.
    Because different ores have different hardness, abrasiveness, moisture content and particle characteristics, we recommend selecting equipment based on the specific material rather than using a standard configuration for every project.

    Can your crushers handle hard and abrasive metal ores?
    Yes. Our crushing equipment can be configured for hard and abrasive materials commonly found in metal mining applications.
    For these projects, we consider the material's hardness and abrasiveness when selecting the crusher type, crushing stages and wear components. Proper equipment matching can help control wear and maintain stable operation over extended production periods.

    What is a typical metal ore crushing and screening process?
    A typical hard-rock metal mining circuit may include vibrating feeding, primary crushing, secondary or tertiary crushing, screening and material transfer.
    The exact process depends on the ore characteristics and the requirements of the downstream grinding or beneficiation process. Some projects may require additional crushing stages, while others can achieve the required product size with a simpler configuration.