1. PYNPUNT GEDREWE OPENING

Managing a premium iron ore crushing plant demands consistent throughput and cost control. Algemene operasionele uitdagings sluit in:
Onbeplande stilstand: Frequent liner changes and mechanical failures in primary crushers halt your entire processing line, duisende per uur in verlore produksie kos.
Inkonsekwente produkgrootte: Fluctuations in feed size and hardness lead to poor fragmentation, overloading downstream circuits like grinding mills, which dramatically increases energy costs.
Hoë instandhoudingskoste: Abrasive iron ore rapidly wears crusher components, resulting in excessive spending on replacement parts and significant labor hours for upkeep.
Energie ondoeltreffendheid: Older crushing stages often operate at nonoptimal settings, consuming more power per ton of material processed than necessary.

Are you evaluating how to increase plant availability, koste per ton verminder, and achieve a more consistent feed for your beneficiation circuit? The foundation of this efficiency starts with your primary crushing solution.

2. PRODUK OORSIG

Hierdie produkreeks bestaan ​​uit swaardiens, stationary primary gyratory crushers engineered specifically for hightonnage, abrasive iron ore applications. As a private label manufacturer, we provide equipment built to your precise operational specifications and branding requirements.

Operasionele werkvloei:
1. Runofmyne (ROM) iron ore is fed via haul trucks or apron feeder into the crusher’s deep chamber.
2. The eccentrically rotating mantle continuously compresses ore against the concave liners, achieving size reduction through progressive rockonrock crushing.
3. Crushed material discharges via gravity through the bottom setting, ready for secondary crushing or direct conveyor transport.

Toepassingsomvang: Ideaal vir grootskaalse mynbedrywighede met meer as jaarlikse kapasiteit 10 million tonnes of magnetite or hematite ores. Suitable for both greenfield installations and retrofit upgrades.

Beperkings: Nie ontwerp vir laetonnage-operasies nie (< 2 million tonnes annually) or for processing highly plastic or sticky materials without specific feed system modifications.

3. KERNKENMERKE

Gepatenteerde kamermeetkunde | Tegniese basis: Optimized nip angle and crushing stroke profile | Bedryfsvoordeel: Achieves targeted product size in a single pass more consistently, die hersirkulasielading te verminder | ROI impak: Tot 15% higher throughput compared to conventional chambers of similar intake size

Liner Life Enhancement System | Tegniese basis: Automated liner condition monitoring and wear compensation technology | Bedryfsvoordeel: Maintains crusher setting automatically for stable output; bied voorspellende instandhoudingswaarskuwings | ROI impak: Verleng liner intervalle met 2030%, reducing downtime and part costs

Hybrid Lubrication System | Tegniese basis: Dedicated circuits for bearing lubrication and piston pressure with independent cooling | Bedryfsvoordeel: Ensures reliable operation under high dust load and variable ambient temperatures common in iron ore plants | ROI impak: Reduces risk of bearingrelated catastrophic failure; velddata toon a 40% verbetering in gemiddelde tyd tussen mislukkings (MTBF) for lubrication systems

Intelligente Drive & Beheer integrasie | Tegniese basis: Hightorque synchronous motor paired with variable frequency drive (VFD) beheer | Bedryfsvoordeel: Laat sagte begin toe, power draw optimization, and adjustment of crushing speed to match ore characteristics | ROI impak: Reduces peak electrical demand by up to 35% tydens opstart; optimizes kWh per ton consumed

Modular Concave & Mantle Assembly | Tegniese basis: Gesegmenteerde voeringontwerp met meganiese sluiting | Bedryfsvoordeel: Enables faster liner changes using standard plant maintenance tools; reduces changeout time by up to 50% | ROI impak: Lowers labor costs per maintenance event and increases plant availability

Integrated Dust Sealing & Inperking | Tegniese basis: Multistage labyrinth seals combined with positivepressure air barriers | Bedryfsvoordeel: Effectively contains dust particles at the feed and discharge points, critical for meeting site environmental standards | ROI impak: Minimizes material loss and reduces cleanup costs, protecting downstream equipment from abrasive dust

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (Gemiddeld) | Hierdie Gyratory Crusher Solution | Voordeel (% Verbetering) |
| : | : | : | : |
| Beskikbaarheid (Geskeduleerde bedryfstyd) | 92 94%| 96%+| ~34% toename |
| Tonnage Deurset (tph comparable size) Basislyn = 100%| 100%| 108 115%| Tot 15% hoër |
| Liner Wear Life (Million Tonnes Processed)| Varies by ore abrasiveness| +2030%| 2030% langer lewe |
| Spesifieke energieverbruik(kWh/t)| Basislyn = 100%| 92 95%|58% vermindering |
| Gemiddelde tyd om te herstel(Major Liner Change hours)| ~48 uur| <36 ure|25+% vinniger |

5. TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Konfigureerbaar vanaf 5,000 oor 12,000 ton per uur (tph), depending on model selection and feed conditions.
Kragvereistes: Ry motors van 600 kW tot 1.5 MW. Compatible with mediumvoltage supply (3.3 kV 6.6 kV). Full electrical package including VFDs and control panel is supplied.
Materiaalspesifikasies: Hoofraam gemaak van hoë-integriteit gegote staal. Concave liners available in premium manganese steel alloys or optional composite metal matrix materials for extreme abrasion resistance.
Fisiese afmetings: Voer opening groottes vanaf 1,200 mm aan 1,500 mm. Overall installation footprint is customized per plant layout but is designed to minimize civil works requirements.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 20°C tot +50°C. Dust sealing effective in conditions with airborne particulate levels exceeding 50 mg/m³.

6. TOEPASSINGSSCENARIO'S

LargeScale Hematite Operation – Throughput Expansion

Uitdaging: A major Australian mine needed to increase plant throughput by over 20% sonder om hul primêre breker-voetspoor uit te brei of bestaande vervoerbande te oorlaai.
Oplossing: Replacement of an older primary crusher with a highcapacity gyratory crusher featuring the Patented Chamber Geometry and Intelligent Drive system.
Resultate: Achieved a sustained 22% increase in average hourly tonnage through the primary circuit while reducing specific energy consumption by 7%. The consistent product size reduced bottlenecks at the secondary screening stage.

Magnetite Concentrator – Reducing Downtime

Uitdaging: A Canadian concentrator faced excessive unplanned downtime due to unpredictable liner wear in their primary crusher, causing scheduling conflicts with downstream grinding mills.
Oplossing: Installation of a gyratory crusher equipped with the Liner Life Enhancement System and Modular Concave Assembly.
Resultate: Liner change intervals became predictable within a ±5% window, allowing maintenance to be scheduled during planned mill stops. Total annual downtime attributed to primary crushing was reduced by approximately 180 ure.

7. KOMMERSIËLE OORWEGINGS

Our private label manufacturing model provides flexibility across commercial terms:

Toerustingprysvlakke: Based on capacity rating and material specification choices (bv., standaard vs. premium liners). Options range from core crusher supply only to full packaged stations including feeders, wandelpaaie, and chute work.
Opsionele kenmerke: Gevorderde toestandmoniteringsensors (vibrasie, temperatuur), outomatiese instellingsverstellingstelsels (ASRi), specialized wear protection packages for specific ore geochemistry.
Dienspakkette: Tiered offerings include onsite supervision during commissioning; multiyear liner supply contracts with guaranteed wear rates; remote diagnostic support; and scheduled inspection services.
Finansieringsopsies: We work with international export credit agencies and equipment financing partners to offer leasetoown structures or term loans tailored to project finance requirements.

8. Gereelde vrae

1. How does this equipment integrate with our existing secondary crushing circuit?
The discharge setting is fully adjustable within its designed range to ensure optimal feed size distribution for your cone crushers or HPGRs.

2 What is the expected impact on our overall plant operating costs?
Industry data from comparable upgrades indicates a reduction in total cost per ton of crushed material between $0.15$0 .35 USD , primarily from lower energy use , extended wear part life ,and increased availability .

3 Word prestasiewaarborge aangebied?
Ja . We provide contractual guarantees for rated capacity under defined conditions , spesifieke energieverbruik ,and major component wear life based on your provided ore characterization data .

4 Wat is die aanlooptye vir aflewering ?
Lead times vary based on model complexity but typically range from9to14months exworksforafullycustomizedprimarycrusher . Expedited options may be available .

5 Do you provide supportfor foundation designand installation ?
We supply comprehensive foundation loading diagramsand interface drawings . Onsite technical supervision during installationand commissioningis available as partof our service packages .

6 Canyou accommodateour company’s brandingand documentation standards ?
Asa private label manufacturer ,thisisacore service . Equipment can bebadgedwithyourbrand,and all manuals ,tekeninge,and control system interfacescanbe formattedto your specifications .

7 Howdoesthe intelligent drive systemhandlepowerfluctuations commonatremote mine sites ?
The integrated VFDsystem includes line reactorsand harmonic filteringto protectthe motorfromgrid disturbances .Itcanalsobe configuredfor controlled shutdownsin caseofundervoltage events topreventmechanical damage