Effect of Aggregate Type on Noise Characteristics and Emissions During the Crushing Process

In processes related to the treatment of mineral materials, the crushing stage determines the ability to obtain the required particle-size fraction. At the same time, it is an exceptionally energy-intensive step (accounting for about 5% of global electricity consumption) and one that generates significant environmental impacts, particularly in the form of high noise levels and considerable dust emissions. This study focuses on acoustic issues associated with the operation of crushers equipped with materials of varying hardness. Noise level measurements were carried out and then compared with the machines' operational parameters, such as reduction ratio, throughput, energy consumption, and grain-size distribution. The results indicate that the properties of the processed material have a significant influence on noise emission during the crushing process. The study included various types of materials, such as pebble, basalt, and granite (feed size 16-22 mm), as well as lower-strength materials, including aerated concrete, recycled concrete, and ceramic materials (average particle size of approximately 50 mm), enabling a comparative analysis under controlled operating conditions. The measured noise levels ranged from front position 105.3 dB and side position 105.2 dB, depending on the material type, with the highest values observed for [hard material, e.g., recycled concrete and basalt] and the lowest for [weak material, e.g., aerated concrete]. The differences between extreme cases reached up to the top position 107.6 dB, indicating a strong relationship between material properties and acoustic emission. These findings highlight the importance of material selection in crushing processes and provide a useful reference for reducing noise impact and improving the environmental performance of industrial aggregate production.