How do you calculate crushing energy cost?

Multiply tonnage by cost per ton and the allocation share for the variable cost, then add fixed setup and liner cost. With 1,200 tons x $2.75 x 100% plus $650 fixed, the total is $3,950.

What is the true cost per ton of crushing?

Divide total cost by tonnage. Here $3,950 over 1,200 tons is $3.29 per ton blended, higher than the $2.75 variable rate because the $650 fixed cost spreads across the batch.

Why include a fixed cost in crushing cost?

Liner wear, setup, screen changes and handling do not scale with the next ton; they are incurred per run. Ignoring them understates short-run cost. The $650 fixed cost adds $0.54 per ton on a 1,200-ton batch but far more on a small run.

What is the allocation share for?

When one crusher serves several products, the allocation share assigns a fraction of variable cost to the product you are costing. At 100% the full per-ton cost lands here; at 60% only 60% of it would, with the rest carried by other products.

How does crushing finer change the cost?

Energy per ton climbs steeply with reduction ratio, following Bond-type comminution behavior, so producing a finer product can multiply the cost-per-ton input. Re-run the calculator with the higher rate rather than assuming the coarse-grind number holds.

How do I lower crushing cost per ton?

Spread fixed cost over larger runs, manage liner wear with correct chamber loading, optimize closed-side setting to avoid over-crushing, and run during off-peak power tariffs. On this batch, doubling tonnage would push blended cost back toward the $2.75 variable rate.

Bulk Solids, Mining, Aggregates & Material Processing calculator

Crushing Energy Cost Calculator

Crushing energy cost is the total spend to reduce a given tonnage through a crusher, combining the variable power and wear cost per ton with the fixed setup, liner and handling cost of the run. Quarry and mining cost engineers use it to quote crushed product, compare crusher circuits, and decide whether finer product is worth the extra energy it demands. Comminution is one of the most power-hungry steps in mineral processing, so even a small error in cost per ton compounds across millions of tons. This calculator pins down both the total run cost and the true blended cost per ton you should be quoting.

What this calculator does

Estimate crushing energy cost for crushing energy cost for bulk solids, mining, aggregates, and material processing using plant-floor material, production, quality, capacity, or cost inputs.
a plant team is reviewing crushing energy cost for bulk solids, mining, aggregates, and material processing and needs a clear crushing energy cost for production, quality, capacity, maintenance, purchasing, or costing decisions
It totals crushing cost by adding the allocated variable cost (tonnage times cost per ton times allocation share) to the fixed liner, setup and handling cost.

Formula used

Allocated crushing energy cost = crushing energy cost material quantity × crushing energy cost cost per ton × allocation share
Crushing Energy Cost = allocated cost + fixed cost

Inputs explained

Tonnage crushed:
Energy cost per ton crushed:
Share of crushing cost allocated to this product:
Fixed liner, setup and handling cost:

How to use the result

Use it when quoting a crushed product, comparing crusher settings or circuits, or attributing shared crushing cost across multiple products.
It treats variable cost per ton as constant, but real energy per ton rises sharply as you crush finer or feed harder, abrasive rock, so a single rate understates fine-grind runs.

Common questions

How do you calculate crushing energy cost? Multiply tonnage by cost per ton and the allocation share for the variable cost, then add fixed setup and liner cost. With 1,200 tons x $2.75 x 100% plus $650 fixed, the total is $3,950.
What is the true cost per ton of crushing? Divide total cost by tonnage. Here $3,950 over 1,200 tons is $3.29 per ton blended, higher than the $2.75 variable rate because the $650 fixed cost spreads across the batch.
Why include a fixed cost in crushing cost? Liner wear, setup, screen changes and handling do not scale with the next ton; they are incurred per run. Ignoring them understates short-run cost. The $650 fixed cost adds $0.54 per ton on a 1,200-ton batch but far more on a small run.
What is the allocation share for? When one crusher serves several products, the allocation share assigns a fraction of variable cost to the product you are costing. At 100% the full per-ton cost lands here; at 60% only 60% of it would, with the rest carried by other products.
How does crushing finer change the cost? Energy per ton climbs steeply with reduction ratio, following Bond-type comminution behavior, so producing a finer product can multiply the cost-per-ton input. Re-run the calculator with the higher rate rather than assuming the coarse-grind number holds.

Last reviewed 2026-05-12.