1. PYNPUNT GEDREWE OPENING

Stygende bedryfskoste en onvoorspelbare beskikbaarheid erodeer jou primêre vergruiskring se winsgewendheid? Key challenges in gyratory crusher operations directly impact your bottom line:
Ongeskeduleerde stilstand: Bearing failures or mainshaft issues can halt your entire processing line for days, honderde duisende in verlore produksie kos.
Hoë instandhoudingskoste: Gereeld, laborintensive liner changes and component wear consume both maintenance budgets and valuable operating hours.
Inkonsekwente deurset & Produk Grootte: Fluktuasies in voermateriaal of slytasie oor tyd lei tot afwykende produk, creating bottlenecks and reducing downstream efficiency.
Oormatige energieverbruik: Older or inefficient designs draw more power per ton processed, a fixed cost that significantly impacts operating margins.

Hoe bereik jy hoër deurset met groter betroubaarheid terwyl jy die totale koste van eienaarskap beheer? The solution requires a crusher engineered not just for peak performance, maar vir volgehoue, predictable operation under the most demanding conditions.

2. PRODUK OORSIG

The Custom Gyratory Crusher is a heavyduty, primary crushing machine designed for hightonnage, continuous operation in largescale mining and aggregate production. It performs compressive crushing via a gyrating mantle within a concave hopper.

Operasionele werkvloei:
1. Voerinname: Runofmyne (ROM) ore or large quarry rock is directly dumped into the top of the crusher’s deep, nonchoking concave.
2. Kompressiewe verplettering: The eccentrically gyrating mantle repeatedly advances and recedes from the concave liners, applying massive compressive force to reduce material size.
3. Ontladingsinstellingsbeheer: The crushed product exits through the adjustable bottom setting (ABS), met grootte bepaal deur die geslote kant instelling (CSS) between the mantle and concave at their lowest point.
4. Ontslag & Transport: Sized material is discharged onto a primary conveyor for transport to the next stage of processing.

Toepassingsomvang: Ideal for primary crushing of abrasive hard rock (ystererts, kopererts, graniet), hightonnage aggregate production, and heap leach applications requiring coarse product. Not recommended for lowtonnage operations, soft or nonabrasive materials only, or sites with severe space constraints where a jaw crusher may be more appropriate.

3. KERNKENMERKE

Patented QS™ Quill Shaft System | Tegniese basis: Isolated eccentric motion with hydrostatic lubrication | Bedryfsvoordeel: Eliminates metaltometal contact in the eccentric assembly, drastically reducing wear and risk of catastrophic failure | ROI impak: Velddata wys tot 40% longer service intervals for the eccentric system and a documented 60% vermindering in verwante ongeskeduleerde stilstand.

INTEGRAL™ Concave & Mantle Liner System | Tegniese basis: Interlocking alloy segments with optimized chamber geometry | Bedryfsvoordeel: Provides more consistent product gradation throughout liner life and reduces changeout time by up to 30% compared to traditional designs | ROI impak: Lower liner cost per ton crushed and increased crusher availability for production.

SMARTSENSE™ Bearing Monitoring | Tegniese basis: Integrated vibration, temperatuur, and pressure sensors on critical bearings | Bedryfsvoordeel: Your maintenance team receives realtime health data and predictive alerts, enabling conditionbased maintenance planning | ROI impak: Voorkom onverwagte laerfoute, protects against secondary damage to shafts and housings.

HYDROSET® PLUS Chamber Clearing & Aanpassing | Tegniese basis: Dualfunction hydraulic ram system for setting adjustment and automated chamber clearing | Bedryfsvoordeel: Operators can adjust CSS under load or clear a stalled cavity remotely in minutes from the control room | ROI impak: Maksimeer uptyd; eliminates hours of manual clearing efforts and associated safety risks.

HEAVYDUTY Spiral Bevel Gear & Pinion | Tegniese basis: Forged alloy steel gears with computeroptimized tooth profile | Bedryfsvoordeel: Transmits high torque smoothly with minimal noise and vibration, even under uneven loading conditions | ROI impak: Industry testing demonstrates a typical service life extension of 25% over standard gear sets under comparable duty cycles.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaardgemiddeld | Custom Gyratory Crusher Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Beskikbaarheid (Geskeduleerde looptyd) | 9294% | 96.5%+ | +35% |
| Liner ChangeOut Tyd (Ure) | 2436 uur | 1620 uur | ~40% vinniger |
| Energieverbruik (kWh/t) Baseline Ore| 0.8 1.2 kWh/t| 0.65 0.9 kWh/t| Tot 20% Meer doeltreffend |
| Gemiddelde tyd tussen mislukking (MTBF) Eccentric System| ~12,000 hrs| >18,000 uur| +50% Betroubaarheid |

5. TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Konfigureerbare modelle van 2,000 tph tot verby 10,000 tph.
Voer opening: Van 1,070 mm (42”) tot 1,520 mm (60”) afhanklik van model.
Motor Power Requirement: Tipies 375 kW aan 750 kW (500 HP aan 1000 HP+), verskaf by 6.6 kV or as required.
Totale gewig: Reeks van ongeveer 150 ton tot oor 400 ton vir grootste konfigurasies.
Sleutel materiaal spesifikasies:
Hoofraam & Top dop: Highstrength fabricated steel with stressrelieving treatment.
Mainshaft: Forged from highalloy nickelchromiummolybdenum steel.
Konkaaf & Mantelvoerings: Mangaan staal legerings (14%18% Mn), optional chromewhite iron or composite alloys for specific abrasion/corrosion applications.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 40°C tot +50°C. Dust seals rated for harsh environments; opsionele verwarming/verkoelingstelsels beskikbaar.

6. TOEPASSINGSSCENARIO'S

Grootskaalse Kopermynuitbreiding

Uitdaging: A planned expansion required a primary crusher capable of handling an additional 8 million tonnes per annum of highly abrasive porphyry ore without increasing footprint or headcount disproportionately.
Oplossing: Installation of one Custom Gyratory Crusher with INTEGRAL™ liners configured for coarse crushing ahead of SAG mills.
Resultate: Behaal volgehoue ​​deurset van 4,500 tph at a consistent P80 of 150mm. Voertuiglewe het met gemiddeld van 15%, contributing to a calculated total cost per tonne reduction of approximately $0.12 across the crushing circuit.

Hoëproduksie Granietsteengroef

Uitdaging: Frequent downtime due to tramp metal events causing damage and lengthy cavity clearing procedures was limiting annual output targets.
Oplossing: Implementation of our gyratory crusher equipped with the HYDROSET® PLUS system and SMARTSENSE™ monitoring.
Resultate: Cavity clearing events reduced from an average operational delay of 8 ure tot onder 45 minutes per incident. Annual plant availability increased by over 300 ure (12+ dae), directly translating to an additional ~450k tonnes crushed per year within existing shifts.

7 KOMMERSIËLE OORWEGINGS

Equipment pricing is structured into three primary tiers based on size/capacity (CGC50 Series, CGC60 Series, CGC72 Series) with base configurations including core drive system controls motor starter lubrication unit

Opsionele kenmerke sluit in:
Advanced automation packages remote diagnostic telemetry special alloy liner packages dust suppression ring

Dienspakkette word afsonderlik aangebied:
Brons (Basiese waarborg) Silwer (Planned Inspection & Parts Discount) Goud (FullService Contract including scheduled labor parts predictive monitoring)

Financing options are available through our partners including capital lease operating lease project financing terms typically structured over years

Gereelde vrae

Wat is die tipiese installasie tydlyn?
From delivery onsite mechanical erection electrical connection commissioning full operation typically requires weeks depending on foundation readiness site support

How does this crusher integrate with my existing control system?
The crushers PLC is designed for interoperability providing standard communication protocols Modbus TCP/IP Profibus We supply full interface documentation

Can you provide wear part cost guarantees?
Yes we offer guaranteed maximum wear part cost per tonne contracts based on your specific feed material analysis providing predictable longterm budgeting

Wat is jou betalingsvoorwaardes?
Standard commercial terms involve progress payments tied key milestones delivery acceptance Final payment due upon successful completion performance run

Bied jy operateur opleiding aan?
Comprehensive training is included covering safe operation routine maintenance troubleshooting conducted both at commissioning at your facility