1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your primary crushing circuit’s profitability? Key challenges in hightonnage primary crushing include:

Unscheduled Downtime: Premature wear or failure of critical components like mantles and concaves leads to production halts, costing thousands per hour in lost throughput.
Inconsistent Feed Handling: Bridging, segregation, and uneven feed distribution from haul trucks cause cycle stress, reduced capacity, and accelerated wear patterns.
High Maintenance Burden: Traditional designs require extensive labor and time for wear part inspection and replacement, increasing direct labor costs and safety exposure.
Energy Inefficiency: Older or poorly optimized gyratory crushers consume excessive power per ton of material processed, directly impacting operational expenditure.
Product Quality Issues: Poorly controlled discharge settings lead to inconsistent product size distribution, causing bottlenecks in downstream processing stages.

Is your operation equipped to handle increasingly hard or abrasive ores while maintaining costperton targets? The solution requires a fundamental reassessment of your primary crushing asset.

2. PRODUCT OVERVIEW: BULK GYRATORY CRUSHER

A Bulk Gyratory Crusher is a heavyduty, stationary primary crusher engineered for the first stage of size reduction in hightonnage mining and aggregate operations. It is designed to accept runofmine feed directly from haul trucks and reduce it to a conveyable product for further processing.

Operational Workflow:
1. Feed Acceptance: Direct dump from haul trucks into the crusher’s robust feed hopper, designed to minimize bridging.
2. Crushing Action: A gyrating mantle within a fixed concave applies compressive force to break large rocks (often +1m in size) against the chamber walls.
3. Progressive Reduction: Material travels down the crushing chamber, being repeatedly crushed to smaller sizes until it reaches the discharge setting.
4. Discharge: Crushed material exits through the discharge opening onto a main conveyor belt for transport to the next stage.

Application Scope & Limitations:
Scope: Ideal for highcapacity (5,000 15,000+ tph) primary crushing of hard rock, ore, and abrasive materials in mining, largescale quarrying, and major construction projects.
Limitations: Not suitable for lowtonnage operations (< 2,000 tph), recycling applications with high metal content, or as a secondary/tertiary crusher. Requires significant foundational support and capital investment.

3. CORE FEATURES

Patented Concave Design | Technical Basis: Segmented, reversible alloy steel sections | Operational Benefit: Extends service life by up to 30%, allows for staged replacement during planned maintenance | ROI Impact: Reduces part cost per ton and limits downtime events.

Integrated Automatic Setting Regulation | Technical Basis: Hydraulic adjustment with realtime position sensors | Operational Benefit: Maintains target CSS (Closed Side Setting) continuously without manual intervention for consistent product gradation | ROI Impact: Improves downstream circuit efficiency by up to 15% and reduces manual adjustment labor.

Advanced Bearing Monitoring System | Technical Basis: Multipoint temperature and vibration sensors with predictive analytics | Operational Benefit: Provides early warning of lubrication issues or mechanical stress, enabling conditionbased maintenance | ROI Impact: Prevents catastrophic bearing failure, avoiding weeks of downtime and sixfigure repair costs.

Spiderless Design (where applicable) | Technical Basis: Eliminates the traditional spider bridge assembly | Operational Benefit: Reduces crusher head weight by up to 40%, simplifies mantle changeout procedures significantly | ROI Impact: Cuts planned maintenance time by over 50%, increasing annual available operating hours.

HighCapacity Lubrication System | Technical Basis: Dualpump circulation with failsafe cooling and filtration | Operational Benefit: Ensures optimal bearing performance under peak load conditions in dusty environments | ROI Impact: Directly extends major component lifespan, protecting the core asset investment.

Intelligent Load & Feed Control Interface| Technical Basis: PLC integration with power draw monitoring and feed rate control logic| Operational Benefit| Automatically regulates feeder speed based on realtime crusher load| optimizing throughput while preventing choking or empty running| ROI Impact| Maximizes throughput within design limits| improving energy efficiency by optimizing kWh/ton.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | Bulk Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Annual) | 92 94% | > 96% documented availability| +24% improvement |
| Mantle ChangeOut Time (Hours)| 24 36 hours| < 18 hours with tooling system| Up to 50% reduction |
| Energy Consumption (kWh/ton)| Varies by ore; baseline = X kWh/t| Field data shows consistent X10% kWh/t reduction at rated capacity.| Up to 10% improvement |
| Wear Life Concaves (Million Tons)| Varies widely with abrasiveness.| Documented increases of 2030% via material & design.| +2030% improvement |
| Throughput at Same CSS (tph)| Baseline model capacity.| Demonstrated 58% higher throughput due to chamber optimization.| +58% improvement |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from approximately 3,500 to over 15,000 metric tons per hour (tph), dependent on feed material and discharge setting.
Motor Power: Typically between 450 kW to over 1 MW (600 1,500 HP), supplied at voltages of 6.6 kV or medium voltage as required.
Feed Opening: Gape sizes from ~1,000 mm x ~1,400 mm up to ~1,800 mm x ~2,800 mm for extralarge models.
Main Frame & Concaves: Fabricated from highstrength steel; concaves available in premium manganese steel alloys or composite designs for specific abrasion/impact conditions.
Physical Dimensions & Weight: Significant footprint; total installed weight can range from ~300 tonnes for midsize models to over >800 tonnes for largest units.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C with appropriate lubrication systems; dustsealed construction standard.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: An existing mine expansion required a primary crusher capable of handling harder ore zones while integrating into a constrained brownfield site with limited maintenance access windows.Solution: Installation of a modern Bulk Gyratory Crusher featuring a spiderless design for easier maintenance.Results: Achieved sustained throughput of over 8,500 tph; mantle replacement time reduced from historical plant average of 32 hours down to 16 hours, directly adding available production days annually.

HighAbrasion Granite Quarry

Challenge: A quarry producing road base aggregates faced concave wear life below industry average, leading to frequent costly shutdowns.Solution: Implementation of a Bulk Gyratory Crusher equipped with patented segmented reversible concaves.Results: Concave service life extended by 28%, reducing annual wear part costs by an estimated $180,000 USD while improving product consistency.

7. COMMERCIAL CONSIDERATIONS

Equipment pricing is tiered based on size/capacity model:
Standard Duty Models (<6000 tph)
Heavy Duty Models (6,000 – 10,000 tph)
Super Duty Models (>10⁰_{00 tph)}

Optional features include advanced predictive monitoring software packages, automated lubrication systems, special alloy wear packages,and custom feed hopper configurations.

Service packages range from basic commissioning support through comprehensive multiyear performance contracts including parts, preventive maintenance,and remote monitoring.

Financing options are available through manufactureraffiliated programs, including leasetoown structuresand project financing tailoredfor large capital expenditures.

8. FAQ

Q: How does this equipment integrate with our existing PLC/SCADA control system?
A: The crusher's control system is designed for standard industrial communication protocols(Modbus TCP/IP Profinet). Our engineering team provides interface specificationsfor seamless integration into your plantwide control network.

Q: What is the expected impact on our overall plant throughput?
A: By providing a more consistentand optimally sized feedto your secondary circuit field data typically shows downstream efficiency gainsof 515%. This reduces bottlenecksand maximizes overall plant capacity.

Q: Are there financing options availablefor this capital expenditure?
A: Yes we offer several commercial modelsincluding traditional purchasecapital leaseand performancebased leasing structures.Terms are tailoredto project scopeand financial requirements.

Q: What levelof technical supportis provided during installationand commissioning?
A: Commissioning is supervisedby factorytrained engineers.We provide comprehensive operational trainingfor your crewswith ongoing technical supportvia remote diagnosticsand onsite service contractsas required.

Q: How does this equipment handle variationsin feed material hardnessor size?
A: The hydraulic adjustment systemallows operatorsor automated control loopsto adjustthe CSSin minutes.The robust designand intelligent load controlsystemare specifically engineeredto handle normal variationsin runofmine materialwithout damage.

Q: What arethe key factorsin determiningthe correct model sizefor our operation?
A: Sizingis basedon three core parameters:maximumfeed size(gape requirement)desiredcapacity(tph)andthe work index(hardness/abrasiveness)of your material.A detailed analysisof your ore bodyor deposit characteristicsis recommended.