1. فتحة مدفوعة بنقطة الألم

تعد إدارة دائرة سحق خام الحديد أمرًا مميزًا, تحديات مكلفة. Are you experiencing persistent bottlenecks that limit your plant’s rated throughput? Are unscheduled maintenance stops and premature wear part failures eroding your operating budget and creating unpredictable downtime? Is inconsistent product sizing leading to inefficiencies in downstream grinding and processing, ultimately affecting pellet or sinter quality? بالإضافة إلى, does the total cost of ownership for your primary crushing stage—factoring in energy consumption, بدائل الخطوط الملاحية المنتظمة, and labor—exceed initial projections? These operational hurdles directly impact profitability. السؤال المركزي لمديري المصانع هو هذا: كيف يمكنك تحقيق موثوقة, hightonnage reduction of abrasive iron ore while controlling operational costs and maximizing plant availability?

2. نظرة عامة على المنتج

This product is a كسارة جيراتوري الأولية engineered specifically for highcapacity iron ore processing. It is designed as the first critical stage in a mineral processing plant, receiving runofmine (ذاكرة للقراءة فقط) feed directly from the pit.

سير العمل التشغيلي:
1. تناول الأعلاف: خام الحديد ROM (يصل حجم الكتلة إلى 1.5 متر) is dumped into the crusher’s deep, قادوس الاستقبال غير الخانق.
2. عمل سحق: A centrally mounted mantle gyrates within a concave bowl, applying compressive force to break the ore against itself.
3. تسريح: Crushed material exits through the bottom setting (CSS), with product size typically ranging from 150mm to 250mm for feed to secondary crushing or SAG mill circuits.

نطاق التطبيق & القيود:
نِطَاق: Ideal for largescale mining operations with high daily tonnage requirements (>10,000 MTD). Suited for processing hard, abrasive hematite and magnetite ores.
القيود: Not designed for final product sizing or for processing materials with high clay or moisture content without adequate prescreening/scalping. يتطلب أساسًا خرسانيًا مستقرًا ومساحة كبيرة للتركيب والصيانة.

3. الميزات الأساسية

تصميم مقعر حاصل على براءة اختراع | الأساس الفني: مجزأة, reversible alloy steel segments | المنفعة التشغيلية: يطيل عمر الخدمة بنسبة تصل إلى 30% by allowing rotation and use of multiple wear surfaces before replacement | تأثير عائد الاستثمار: Reduces liner inventory costs and downtime for concave changes

تنظيم الإعداد التلقائي المتكامل | الأساس الفني: نظام الضبط الهيدروليكي مع أجهزة استشعار الموضع | المنفعة التشغيلية: Allows operators to adjust the crusher discharge setting in minutes without stopping the process | تأثير عائد الاستثمار: Maintains optimal product size for downstream efficiency, increasing overall circuit throughput by an estimated 25%

نظام التشحيم مع مراقبة الحالة | الأساس الفني: Dualcircuit filtration and temperature/pressure sensors feeding to plant DCS | المنفعة التشغيلية: Provides continuous protection of critical bearings; alerts personnel to potential issues before failure occurs | تأثير عائد الاستثمار: Prevents catastrophic bearing damage, a failure that can result in over 200 ساعات من الإنتاج الضائع

SpiderMounted Dump Hopper & Seal | الأساس الفني: Reinforced design with multistage dust seal system | المنفعة التشغيلية: Effectively contains dust at the feed point and prevents contaminant ingress into the main bearing assembly | تأثير عائد الاستثمار: Reduces environmental emissions compliance costs and extends bearing life in dusty conditions

تصميم العمود الرئيسي للخدمة الشاقة | الأساس الفني: Forged alloy steel shaft with optimized fatigue resistance profile | المنفعة التشغيلية: Provides exceptional strength to handle tramp steel and uncrushable material events without shaft deflection or failure | تأثير عائد الاستثمار: Eliminates unplanned outages related to shaft failure, a primary cause of extended downtime in primary crushing

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (متوسطات المنافسين) | This Primary Gyratory Crusher Solution | ميزة (% تحسين) |
| : | : | : | : |
| التوفر (وقت التشغيل المقرر) | 9294% | 96%+ documented field average over 24 شهور | ~34% تحسن |
| حياة الخطوط الملاحية المنتظمة (Million Tons/Set) Hematite Ore| 4.5 5.5 طن | 6.0 7.0 طن verified at multiple sites| ~1520% تحسن |
| استهلاك الطاقة المحددة (كيلوواط ساعة/طن) | 0.18 0.22 كيلووات ساعة/طن | 0.15 0.17 كيلووات ساعة/طن based on installed motor vs. throughput data| تحسن بنسبة 18% |
| Tramp Iron PassThrough Recovery Time| المقاصة اليدوية; hours of downtime| Hydraulic clearing system; 80% reduction in event duration |

5. المواصفات الفنية

تسمية النموذج: PGC60110
فتح الأعلاف: 1,520 مم (60 بوصة)
نطاق القدرة الاسمية: 3,500 7,500 متف (dependent on ore characteristics and discharge setting)
الطاقة المثبتة: 600 كيلوواط (800 HP) electric drive motor
رمح الرئيسي: Forged ES355 alloy steel
مقعر & Mantle Material: ASTM A128 Manganese Steel with proprietary heat treatment
الوزن الإجمالي (كسارة فقط): ~275 metric tons
Top Shell Diameter: ~4.8 meters
نطاق درجة حرارة التشغيل: 30درجة مئوية إلى +45 درجة مئوية (with appropriate lube oil specifications)
التحكم في الغبار: Integral connection points for plant dust extraction system.

6. سيناريوهات التطبيق

LargeScale Open Pit Mine – Australia Challenge:

A major hematite operation faced declining feed grades, requiring higher throughput volumes through their primary crushing station to maintain annual production targets. Their existing crusher was unable to achieve higher tonnage without excessive wear and energy costs.

حل:

Implementation of one PGC60110 Primary Gyratory Crusher with the integrated automatic setting system.

نتائج:

Within six months of commissioning:
Sustained throughput increased by 18%, meeting upgraded plant demands.
Energy cost per ton crushed decreased by 16%.
Annual planned maintenance hours were reduced by 120 hours due to extended liner intervals.

Magnetite Concentrator – North America Challenge:

The client’s new greenfield project required a primary crusher capable of handling extremely hard magnetite ore while guaranteeing >95% availability as the single point of failure for the entire coarse ore circuit.

حل:

Installation of two PGC60110 crushers configured with full condition monitoring on lube systems and main bearings.

نتائج:

Over the first two years of operation:
Achieved an average operational availability of 96.7%.
Successfully passed multiple tramp metal events without damage via the hydraulic release system.
Condition monitoring provided actionable data that allowed scheduling of a bearing inspection during a planned plant shutdown, avoiding a predicted inservice failure.

7 الاعتبارات التجارية

Our commercial model is structured around providing predictable total cost outcomes.

مستويات تسعير المعدات: Pricing is based on configuration.
التكوين الأساسي: Core crusher assembly with standard lubrication unit.
التكوين المتقدم: Includes automatic setting regulation (ASR), أجهزة استشعار مراقبة الحالة المتقدمة, and upgraded dust sealing.
Turnkey SkidMounted Unit: Crusher preassembled on a structural skid base with walkways, سلالم, and integrated lubrication system for faster installation.

الميزات الاختيارية & ترقيات: Wear monitoring systems via concave wear sensors; premium ceramic composite liners for specific abrasion zones; custom discharge conveyor flanges; extended warranty packages on major castings.

حزم الخدمة:
اتفاقية الصيانة المخططة: عمليات التفتيش المجدولة, oil analysis programs, والدعم الفني.
Liner Service Contract: Guaranteed liner life performance with fixedcostperton replacement parts.
عقد الخدمة الكاملة: يغطي جميع الأجزاء (يرتدي & ميكانيكية), تَعَب, and field service engineering for a fixed annual fee.

خيارات التمويل: We offer several capital solutions including traditional equipment financing/leasing through our partners or performancebased contracting models where payments can be partially linked to achieved availability or throughput guarantees.

8 التعليمات

1.Q What is the lead time from order placement to delivery?
A For standard models like the PGC60110 lead times are typically between 912 months due to extensive forging and machining requirements for major components like the main shaft and top shell castings

2.Q How does this crusher integrate with our existing PLC/SCADA control system?
A The unit comes standard with an AllenBradley ControlLogix PLC local panel All critical operational data pressure temperature motor status ASR position are communicated via industrystandard Modbus TCP/IP or Ethernet/IP protocols allowing straightforward integration into your wider plant control network

3.Q What are your recommendations regarding feed size distribution?
A For optimal performance we recommend ROM feed where no more than XNUMX% exceeds XNUMX times the nominal feed opening size Consistent feeding using a vibrating grizzly feeder or apron feeder is critical Our engineering team can review your specific mine plan geology data

4.Q Do you provide installation supervision?
A Yes we offer optional expert field service supervision during installation commissioning This service ensures correct mechanical alignment electrical connection verification lubrication system flushing procedure adherence which directly impacts longterm reliability

5.Q What are typical spare parts inventory recommendations?
A We provide sitespecific recommendations based on your operating schedule However we maintain regional stockholding centers globally offering XNUMX/XNUMX emergency parts dispatch Critical spares like main shaft step washers eccentric bushings should be held onsite per our recommended list

6.Q Can you guarantee performance metrics like capacity or liner life?
A Formal performance guarantees are provided as part of our commercial proposal following detailed review analysis of your representative ore samples geotechnical data These guarantees form part binding contract subject defined test protocols postcommissioning