1. فتحة مدفوعة بنقطة الألم

Managing a limestone quarry or processing plant presents distinct, تحديات مكلفة. Are you experiencing persistent bottlenecks that limit your operation’s true capacity? تشمل نقاط الألم الشائعة:
Excessive Primary Crusher Downtime: Bridging and clogging at the primary crushing stage due to oversized, slabby feed material halts entire production lines, تكلف الآلاف في الساعة من الإنتاجية المفقودة.
Unpredictable Feed Size to Downstream Processes: Inconsistent fragmentation from the muck pile leads to poor crusher performance, increased wear on conveyor systems, and inefficient sizing for kiln feed or aggregate products.
High Operational Costs from Secondary Breakage: Reliance on hydraulic hammers for secondary breaking is laborintensive, slow, and incurs substantial costs in tool wear, وقود, and equipment maintenance.
Safety and Vibration Concerns: Secondary breaking and inefficient primary blasting can generate excessive ground vibration, posing regulatory compliance risks and community relation issues near sensitive boundaries.

السؤال المركزي هو: how can you achieve a consistently fragmented, optimally sized feed from the face to your primary crusher to maximize plant uptime and reduce downstream processing costs?

2. نظرة عامة على المنتج

The solution is a highcapacity Primary Gyratory Crusher engineered specifically for hightonnage limestone mining operations. This equipment serves as the cornerstone of your raw material handling system, designed to accept runofquarry limestone directly from the haul trucks.

سير العمل التشغيلي:
1. Direct dump of shot limestone from haul trucks (up to 2meter top size) into the crusher’s large feed hopper.
2. The gyrating mantle within the fixed concave crushes material via compressive force, reducing it by a factor of 6:1 ل 8:1.
3. Crushed product discharges onto the main plant conveyor at a consistent size (عادة <250مم), ready for secondary crushing or screening.

نطاق التطبيق: مثالية لعمليات المحاجر واسعة النطاق التي يتجاوز إنتاجها السنوي 1 مليون طن. It is designed for continuous, 24/7 operation under heavy load.

القيود: Not suitable for smallscale quarries or portable crushing setups due to significant foundation requirements and capital investment. Requires consistent, planned maintenance shutdowns.

3. الميزات الأساسية

Patented NonChoking Concave Profile | الأساس الفني: Steepsided feed opening with optimized curvature | المنفعة التشغيلية: Eliminates bridging of slabby limestone; ensures continuous material flow even with high clay content | تأثير عائد الاستثمار: Reduces crusher stall events by up to 90%, directly increasing available crushing hours

تنظيم الإعداد التلقائي المتكامل (ASR) نظام | الأساس الفني: Hydropneumatic adjustment with realtime position sensors | المنفعة التشغيلية: Maintains target discharge setting without manual intervention; compensates for mantle wear automatically | تأثير عائد الاستثمار: Delivers consistent product sizing (+/ 5% tolerance), improving downstream efficiency and reducing product waste

HeavyDuty Main Shaft & Spider Assembly | الأساس الفني: Forged alloy steel shaft with premium bronze bushing design | المنفعة التشغيلية: Withstands extreme shock loads from uncrushable material; provides reliable service life exceeding 10 years in abrasive limestone | تأثير عائد الاستثمار: Lowers lifetime cost of ownership via extended major component life and reduced risk of catastrophic failure

Lube System with Dual Coolers & Filtration | الأساس الفني: Redundant cooling circuits and offline filtration unit | المنفعة التشغيلية: Maintains optimal bearing temperature in highambient conditions; continuously purges contaminants from oil | تأثير عائد الاستثمار: Extends bearing service intervals by up to 50%, decreasing lubrication costs and unplanned downtime

Smart Chamber Design & Wear Monitoring | الأساس الفني: Modular concave segments with embedded wear sensors | المنفعة التشغيلية: Allows for strategic rotation/replacement of wear parts; provides predictive maintenance data on remaining liner life | تأثير عائد الاستثمار: Optimizes liner changeout schedules during planned stops, maximizing utilization and parts investment

التشحيم المركزي & PLC Control Hub | الأساس الفني: Automated singlepoint greasing for all bearings integrated into plant control system | المنفعة التشغيلية: Simplifies routine maintenance; provides operators with realtime performance dashboards and fault diagnostics | تأثير عائد الاستثمار: Reduces daily lubrication labor by 75% and shortens troubleshooting time significantly

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (Cone/Jaw Crusher Plants) | الحل الأساسي للكسارة الدورانية | ميزة (% تحسين) |
| : | : | : | : |
| التوفر (الجهوزية)| 8590% due to bridging & more frequent liner changes| 9496% through nonchoking design & عمر أطول للارتداء| +7% operational availability |
| Tonnage per Installed HP| Lower ratio due to intermittent feeding & تصميم الغرفة| Higher ratio via continuous crushing action & optimal kinematics| +1520% energy efficiency |
| Feed Top Size Capability| Limited by gape dimension; often requires prescreening| Accepts larger direct dump feed (up to 2m), simplifying loadout| Eliminates prescreening stage |
| التكلفة لكل طن (ارتداء أجزاء)| Higher cost due to faster wear rates in abrasive limestone| Lower cost via massive liner design & strategic wear monitoring| 25% cost per ton crushed |
| Manpower for Operation| Often requires dedicated crusher operator/feeder watcher| Fully automated operation integrated with PLC/SCADA system| 1 FTE requirement |

5. المواصفات الفنية

Model Designation: GY5460 HD Limestone
نطاق السعة: 2,500 - 4,500 طن في الساعة (dependent on CSS and material work index)
فتح الأعلاف: 1,370 مم
الحد الأقصى لحجم التغذية: 2,000 مم (slabby limestone)
Nominal Discharge Setting Range: 150 - 250 مم
الطاقة المثبتة: 450 كيلوواط (600 HP) electric drive
الوزن الإجمالي (كسارة فقط): ~275 tonnes
مواصفات المواد الرئيسية: عباءة & Concaves – Manganese steel alloy with patented workhardening matrix; Main Shaft – Forged 34CrNiMo6; Base Frame – Fabricated heavyduty steel.
الأبعاد المادية (طول × عرض × ارتفاع): ~6.5m x ~5m x ~4.5m (above foundation).
نطاق التشغيل البيئي: مصممة لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +50 درجة مئوية. Dust sealing rated for IP66.

6. سيناريوهات التطبيق

Large Cement Plant Quarry Integration

تحدي: A major cement producer faced inconsistent kiln feed quality due to fluctuating limestone size from their old jaw crusher circuit, causing inefficiencies in raw mill operation and higher specific energy consumption.
حل: Installation of a GY5460 HD Primary Gyratory Crusher as the new first reduction stage.
نتائج: Achieved a consistent 200mm crusher product. This stabilized raw mill feed, resulting in a documented 8% reduction in specific energy consumption at the mill and a 12% increase in overall plant throughput due to eliminated upstream bottlenecks.

HighVolume Aggregate Quarry Expansion

تحدي: An aggregate producer needed to expand annual output but was constrained by primary crushing capacity. Their existing system required frequent secondary breaking and suffered from daily bridging incidents.
حل: Commissioning of two parallel GY5460 HD crushers fed directly by 90ton haul trucks.
نتائج：Bridging incidents were eliminated. The quarry increased average hourly throughput by over 40%, meeting expansion targets without adding a third shift. Secondary hammer operating costs were reduced by over 60%.

7. الاعتبارات التجارية

Equipment pricing is structured around configuration tiers:
طبقة التكوين الأساسي: يشمل كسارة, محرك السيارة, lubrication system, وضوابط PLC الأساسية.
Advanced Optimization Tier: Adds ASR System, integrated wear monitoring sensors, advanced predictive maintenance software suite.
Turnkey Installation Tier: Full engineering package including foundation design drawings, installation supervision,and commissioning services.

Optional features include dust suppression ring kits,tramp metal detection systems,and custom discharge conveyor flanges.

Service packages are offered as annual Performance Care Agreements covering planned inspections,predictive analytics review,and priority parts supply.Financing options include capital purchase,direct leasetoown models,and throughputbased agreements tailoredfor largescale projects.

8. التعليمات

س1：Is this primary gyratory crusher compatible with our existing downstream secondary cone crushersand screening plant?
أ1：Yes.Field data shows its abilityto producea consistent,fineslimited product optimizes loadingand performanceof downstream stages.Engineering supportis providedto ensure interface compatibilitywith your existing conveyorsand chutework.

Q2：What isthe typical implementation timelinefrom orderto commissioning?
A2：Fora standard model,the lead timeis approximately89 months.Foundation constructioncan proceedin parallel upon receiptof detailed drawings.Onsite erectionand mechanical commissioningtypically require810 weekswith our supervision.

س3：How doesthe automated setting regulationimpact final product specificationfor our aggregate products?
A3：The ASR systemmaintainsa tighter discharge setting tolerance.This directly translatesintoa more consistentfeedfor your secondary/tertiary stages,yielding superior controlover final aggregate gradationand increased yieldof inspecproduct.

س 4：What arethe critical spare partswe should planto stock?
A4：We recommendan initial spare parts kitincluding concave segments,عباءة,bushing kits,and hydraulic cartridge filters.Ourbasedon your specific production forecastand local logisticsupport times.

س5：Can this equipment handlethe occasional siliceous bandor chert nodulefoundin our limestone deposit?
A5：Yes.The heavyduty designincorporatesa hydroset systemthat allows the c rus herto pass uncrushablematerialby temporarily openingthe discharge setting,thereby providingprotection against tramp materialdamage.The robust main shaftassemblyis engineeredfor such shock loads.

س6：What trainingis providedfor our maintenance crew?
A6：Comprehensive trainingis includedcovering operational procedures,scheduled maintenance tasks,troubleshooting usingthe PLC interface,and safety lockout protocols.This consistsof both classroominstructionand handson sessionsduring commissioning.

س7：Are there financing options that align paymentwith achievingprojected production volumes?
A7：Yes.We offer structured financing solutionswhere repayment schedulescan be linkedto operational milestonesor throughput volumes.This helps manageinitial capital outlayand aligns ourobjectiveswith your production success