1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your primary crushing circuit's profitability? For plant managers and engineering contractors, the primary crushing stage is a critical bottleneck where equipment failure carries severe consequences. Common challenges with traditional solutions include:
Excessive Downtime for Maintenance: Frequent liner changes and unexpected mechanical repairs can halt your entire processing line for days, costing thousands per hour in lost production.
Inconsistent Feed Handling: Fluctuations in feed size or moisture content lead to choking, reducing throughput and creating hazardous clearing procedures for your operators.
High Operational Costs: Rising energy consumption per ton of processed material, coupled with the high cost and frequency of wear part replacement, directly impacts your bottom line.
Limited Capacity for Future Expansion: Inflexible equipment that cannot be easily upgraded or adapted to higher throughput demands constrains your site's longterm growth.

Is your current primary crusher a reliable asset or a recurring source of cost and delay? The solution requires a fundamentally robust design engineered for continuous, hightonnage operation.

2. PRODUCT OVERVIEW

The China Gyratory Crusher represents a class of heavyduty, stationary primary crushing equipment designed for the first stage of size reduction in hightonnage mining and aggregate operations. Its core mechanism involves a gyrating mantle within a concave crushing chamber, delivering consistent compressive force to break large feed material (often >1m) down to a manageable size for downstream processing.

Operational Workflow:
1. Feed Intake: Large runofmine ore or quarry rock is directly dumped via haul trucks into the crusher’s deep, unrestrictive feed opening.
2. Compressive Crushing: The eccentrically gyrating mantle continuously compresses material against the stationary concaves, applying progressive breaking force.
3. Discharge: Crushed product exits through the adjustable discharge opening at the bottom of the chamber, with the gap setting determining the final product size.

Application Scope: Ideal for highcapacity (1,500 10,000+ tph) primary crushing applications in metal ore mines (iron, copper, gold), largescale aggregate quarries, and major industrial mineral processing plants.

Key Limitations: This equipment is designed as stationary foundationinstalled machinery. It is not suitable for mobile or semimobile applications without significant structural support. Optimal performance requires consistent, direct feed from a shovel or truck; it is not designed for handling significant volumes of sticky, highplasticity clay materials without preprocessing.

3. CORE FEATURES

Patented Concave Design | Technical Basis: Segmented, alloysteel concave sections with optimized chamber geometry | Operational Benefit: Generates a more consistent product gradation curve and extends wear life by distributing load evenly across multiple segments | ROI Impact: Reduces concave replacement frequency by up to 30%, lowering part costs and associated maintenance downtime.

Integrated Intelligent Control System | Technical Basis: PLCbased automation with realtime pressure & power monitoring | Operational Benefit: Your operators can optimize load distribution and instantly detect anomalies like uncrushable material or uneven wear | ROI Impact: Prevents catastrophic damage events; field data shows a typical 58% improvement in energy efficiency through optimized operation.

Hydroset® Mechanism for CSS Adjustment | Technical Basis: Hydraulic piston supports the mainshaft for closedside setting (CSS) adjustment under load | Operational Benefit: Allows remote adjustment of crusher discharge setting in minutes without stopping production | ROI Impact: Enables rapid product size changes to meet shifting demand, maximizing plant uptime and flexibility.

SpiderMounted Seal System | Technical Basis: Labyrinth & grease purging seal arrangement mounted on the top spider assembly | Operational Benefit: Effectively excludes dust and contaminants from the eccentric bushing and dust seal area | ROI Impact: Dramatically extends bearing life; industry maintenance records indicate a 40%+ increase in time between major overhauls.

Forged Alloy Steel Main Shaft | Technical Basis: Singlepiece main shaft manufactured from highintegrity forged steel | Operational Benefit: Provides unmatched strength and fatigue resistance under extreme cyclical loading conditions | ROI Impact: Eliminates shaft failure risk—a primary cause of extended, multiweek downtime—ensuring longterm structural integrity.

StateLevel R&D Tested Wear Metals | Technical Basis: Manganese steel alloys developed in partnership with national material science institutes | Operational Benefit: Concaves and mantles offer superior workhardening properties under impact abrasion specific to local ore profiles | ROI Impact: Delivers wear life performance comparable to international premium brands at a significantly lower cost per operating hour.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Competitive Gyratory) | China Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Annual)| 92 94% | >96% (Documented) | +24% Uptime |
| Tonnage per Wear Life| Sitedependent baseline | +1525% longer life (verified trials) | +1525% |
| Energy Consumption (kWh/t)| Baseline set at 100% | Optimized chamber flow reduces recirculation load to ~94%| ~6% Reduction |
| Maintenance Downtime (Annual Hours)| 300 400 hoursfor scheduled liner changes & mechanical service| Reduced by integrated tooling & design to ~220280 hours| ~2530% Reduction |
| CSS Adjustment Time| Manual shim adjustment (~48 hours downtime)
Basic hydraulic adjustment (~1 hour)

Typical range based on published industry case studies. |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable models from 1,500 to over 10,000 metric tons per hour (tph), depending on feed material density and product size requirement.
Motor Power: Heavyduty squirrelcage motors ranging from 400 kW to 1,200 kW standard; engineered for hightorque starting under load.
Feed Opening: Gape sizes from 800 mm to 1,500 mm to accept large haul truck deliveries.
Key Material Specifications:
Main Frame & Top Shell: Highstrength carbon steel plate (Q345B equivalent).
Concaves & Mantle Core: ASTM A128 Grade B3/B4 Manganese Steel or proprietary ZGMn18Cr2 equivalent.
Eccentric Assembly & Bushings: Bronze alloy bushings with hardened steel wearing surfaces.
Physical Dimensions / Footprint: Varies significantly by model; typical base diameter ranges from 5m to 9m. Full foundation engineering drawings are provided.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dustproofing meets IP65 standards; special sealing packages available for extreme dust or wet conditions.

6. APPLICATION SCENARIOS

LargeScale Iron Ore Mine – Primary Crushing Station Upgrade

Challenge: An aging jaw crusher installation created a persistent bottleneck at 2,200 tph, requiring frequent maintenance stops every 68 weeks due to wear part failure and frame fatigue cracks.
Solution: Installation of a single heavyduty China Gyratory Crusher with an enlarged feed opening matched to new larger haul trucks.
Results: Throughput increased consistently above design capacity to over 2,800 tph. Annual planned maintenance events were reduced from six major stops to two scheduled inspections. Overall plant availability increased by an estimated annualized value exceeding $1.2M USD in recovered production time alone.

Major Granite Aggregate Quarry – New Greenfield Plant

Challenge: The project required a primary crusher capable of processing extremely hard (>200 MPa compressive strength) granite at >1,600 tph while maintaining tight control over final product shape for highvalue railway ballast specification.
Solution: Deployment of a midrange China Gyratory Crusher equipped with specialized chamber profiles designed for abrasive rock.
Results: The crusher achieved sustained throughput of over tph while producing cubical product meeting all shape specifications. Wear part consumption costs were documented at below initial projections, contributing directly to higher project margins.

Copper Mine Expansion – Secondary Crushing Duty

Challenge: Existing SAG mill feed preparation was inefficient due to inconsistent pebble crusher performance, causing mill throughput fluctuations.
Solution: Implementation of two smaller China Gyratory Crushers configured specifically as secondary units, replacing cone crushers.
Results: Provided more stable, predictable feed size distribution into SAG mills. Mill throughput variability decreased by , leading directly measured gains in overall concentrator recovery rates.

Note: Specific tonnage figures have been generalized as they are commercially sensitive.

7. COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured according tonnage capacity motor power rating
Base Model Tier (tph): Competitive entry point capital expenditure
HighCapacity Tier (tph): Includes enhanced automation package standard duty monitoring sensors
Premium Custom Tier (tph): Full bespoke engineering specific ore characteristics includes advanced predictive maintenance software integration

Optional Features Upgrades
Dual Mass Flywheel System reduces peak motor loads during startup
Advanced Wear Monitoring System uses ultrasonic sensors track liner thickness remotely
Centralized Automated Lubrication System ensures reliability reduces manual intervention

Service Packages
Standard Warranty: months parts labor excluding consumable wear parts
Extended Performance Agreement: years includes scheduled inspections priority parts supply fixed annual fee
FullService Maintenance Contract: Comprehensive coverage including all wear parts labor condition monitoring managed client site team

Financing Options Available through partnered institutions include
Capital Lease structures preserving working capital
Operating Lease options shorter term commitments
Project Financing support large scale greenfield brownfield developments

8. FAQ

Q What existing foundation work required install this gyratory crusher?
A Each model requires specific heavy reinforced concrete foundation designed handle dynamic loads Detailed geotechnical analysis foundation drawings provided early engineering phase ensure compatibility retrofit projects new builds

Q How does this equipment handle tramp metal uncrushable material entering chamber?
A The hydraulic safety release system activates automatically pressure exceeds preset limit allowing mainshaft drop release foreign object Chamber then automatically repositions minimal operator intervention typical reset process completed minutes

Q What typical lead time delivery commissioning?
A Lead times vary model complexity Standard configurations typically available within months order confirmation Complex custom designs may require months Full commissioning supervision operator training included delivery scope ensure rapid rampup design capacity

Q Are wear parts interchangeable other international OEM brands?
A No Our concave mantle designs proprietary dimensions metallurgy Direct interchangeability not possible guaranteed However our pricing structure logistics ensure total cost ownership competitive often lower than sourcing equivalent parts other manufacturers

Q What level technical support available during operation?
A We provide dedicated remote support access engineers via secure connection realtime operational data Additionally regional service centers stock critical spare parts ensure rapid response times unplanned events

Q Can automation system integrate existing plantwide SCADA DCS control room?
A Yes The intelligent control system equipped standard communication protocols Modbus OPC UA allowing seamless integration existing supervisory systems provide operators centralized view critical parameters alarms

Q Are performance guarantees offered with purchase?
A Yes We provide guaranteed minimum capacity based agreed feed material specifications guaranteed maximum power consumption These backed contractual terms subject predefined site conditions feed characteristics