How to find operating cost of crusher plant?

Calculating the operating cost of a crusher plant involves several factors. Here’s a step-by-step guide to help you estimate the cost:

1. Labor Costs:

   • Determine the number of operators needed and their hourly wages.
   • Include costs for any additional supporting staff.

2. Fuel and Energy Costs:

   • Calculate the fuel consumption rates if diesel generators are used.
   • For electric-powered plants, determine the electricity consumption and associated costs.

3. Maintenance and Repair Costs:

   • Estimate the routine maintenance requirement and associated costs for parts and labor.
   • Include costs for any unexpected repairs or breakdowns.

4. Wear & Tear on Equipment:

   • Account for the depreciation of the crusher and other supporting machinery.
   • Determine the lifespan of critical components like the jaw, cone, and impact crushers.

5. Consumables:

   • Include costs for wear parts such as crusher liners, belts, and other consumables.

6. Utilities:

   • Account for water, if used for cooling or dust suppression.
   • Also consider other utilities like compressed air, if applicable.

7. Transportation Costs:

   • If raw materials or finished products need to be transported, include these costs as well.

8. Regulatory and Compliance Costs:

   • Include costs for obtaining and maintaining necessary permits.
   • Factor in costs associated with compliance to environmental and safety regulations.

9. Insurance:

   • Include insurance costs for property, liability, and employee-related insurances.

10. Miscellaneous Costs:

    • Account for any other miscellaneous costs such as administrative expenses, leasing, etc.

Sample Calculation Framework:

1. Labor: \[ \text{Number of operators} \times \text{Hourly wage} \times \text{Operational hours/month} \]

2. Fuel/Energy: \[ \text{Fuel consumption per hour} \times \text{Cost per unit of fuel} \times \text{Operational hours/month} \]

   or

   \[ \text{Energy consumption per hour} \times \text{Cost per kWh} \times \text{Operational hours/month} \]

3. Maintenance: \[ \text{Monthly maintenance cost} \]

4. Wear & Tear: \[ \text{Annual cost of parts replacement} \div 12 \]

5. Consumables: \[ \text{Monthly cost of consumables} \]

6. Transportation: \[ \text{Monthly transportation cost} \]

7. Compliance: \[ \text{Annual compliance cost} \div 12 \]

8. Insurance: \[ \text{Annual insurance cost} \div 12 \]

9. Miscellaneous: \[ \text{Monthly miscellaneous costs} \]

Summing up all these factors will give you a comprehensive estimate of the operating cost for your crusher plant.

Example: Suppose you have the following data (hypothetical):

• Labor: 4 operators, $20/hour, 160 hours/month.
• Fuel: 50 liters/hour, $1.20/liter, 160 hours/month.
• Maintenance: $500/month.
• Wear & Tear: $2400/year.
• Consumables: $300/month.
• Transportation: $1500/month.
• Compliance: $1200/year.
• Insurance: $2400/year.
• Miscellaneous: $200/month.

Calculation:

1. Labor: \[ 4 \times 20 \times 160 = \$12,800 \]
2. Fuel: \[ 50 \times 1.20 \times 160 = \$9,600 \]
3. Maintenance: \[ \$500 \]
4. Wear & Tear: \[ \$2400 \div 12 = \$200 \]
5. Consumables: \[ \$300 \]
6. Transportation: \[ \$1500 \]
7. Compliance: \[ \$1200 \div 12 = \$100 \]
8. Insurance: \[ \$2400 \div 12 = \$200 \]
9. Miscellaneous: \[ \$200 \]

Total Monthly Operating Cost:

\[ 12800 + 9600 + 500 + 200 + 300 + 1500 + 100 + 200 + 200 = \$25,400 \]

By accurately tracking each cost component, you can better manage and potentially reduce your overall operating expenses.