1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y la disponibilidad impredecible están erosionando la rentabilidad de su circuito primario de trituración?? Key challenges in gyratory crusher operations directly impact your bottom line:
Tiempo de inactividad no programado: Bearing failures or mainshaft issues can halt your entire processing line for days, costando cientos de miles en producción perdida.
Altos costos de mantenimiento: Frecuente, laborintensive liner changes and component wear consume both maintenance budgets and valuable operating hours.
Rendimiento inconsistente & Tamaño del producto: Las fluctuaciones en el material de alimentación o el desgaste con el tiempo dan lugar a productos fuera de especificación., creating bottlenecks and reducing downstream efficiency.
Consumo excesivo de energía: Older or inefficient designs draw more power per ton processed, a fixed cost that significantly impacts operating margins.

¿Cómo se puede lograr un mayor rendimiento con mayor confiabilidad y al mismo tiempo controlar el costo total de propiedad?? The solution requires a crusher engineered not just for peak performance, pero por sostenido, predictable operation under the most demanding conditions.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

The Custom Gyratory Crusher is a heavyduty, primary crushing machine designed for hightonnage, continuous operation in largescale mining and aggregate production. It performs compressive crushing via a gyrating mantle within a concave hopper.

Flujo de trabajo operativo:
1. Consumo de alimento: Runofmine (memoria de sólo lectura) ore or large quarry rock is directly dumped into the top of the crusher’s deep, nonchoking concave.
2. Trituración compresiva: The eccentrically gyrating mantle repeatedly advances and recedes from the concave liners, applying massive compressive force to reduce material size.
3. Control de ajuste de descarga: The crushed product exits through the adjustable bottom setting (ABS), con tamaño determinado por la configuración del lado cerrado (CSS) between the mantle and concave at their lowest point.
4. Descargar & Transporte: Sized material is discharged onto a primary conveyor for transport to the next stage of processing.

Ámbito de aplicación: Ideal for primary crushing of abrasive hard rock (mineral de hierro, mineral de cobre, granito), hightonnage aggregate production, and heap leach applications requiring coarse product. Not recommended for lowtonnage operations, soft or nonabrasive materials only, or sites with severe space constraints where a jaw crusher may be more appropriate.

3. CARACTERÍSTICAS PRINCIPALES

Patented QS™ Quill Shaft System | Base técnica: Isolated eccentric motion with hydrostatic lubrication | Beneficio operativo: Eliminates metaltometal contact in the eccentric assembly, drastically reducing wear and risk of catastrophic failure | Impacto del retorno de la inversión: Los datos de campo muestran hasta 40% longer service intervals for the eccentric system and a documented 60% reducción del tiempo de inactividad no programado relacionado.

INTEGRAL™ Concave & Mantle Liner System | Base técnica: Interlocking alloy segments with optimized chamber geometry | Beneficio operativo: Provides more consistent product gradation throughout liner life and reduces changeout time by up to 30% compared to traditional designs | Impacto del retorno de la inversión: Lower liner cost per ton crushed and increased crusher availability for production.

SMARTSENSE™ Bearing Monitoring | Base técnica: Integrated vibration, temperatura, and pressure sensors on critical bearings | Beneficio operativo: Your maintenance team receives realtime health data and predictive alerts, enabling conditionbased maintenance planning | Impacto del retorno de la inversión: Previene fallas inesperadas en los rodamientos, protects against secondary damage to shafts and housings.

HYDROSET® PLUS Chamber Clearing & Ajuste | Base técnica: Dualfunction hydraulic ram system for setting adjustment and automated chamber clearing | Beneficio operativo: Operators can adjust CSS under load or clear a stalled cavity remotely in minutes from the control room | Impacto del retorno de la inversión: Maximiza el tiempo de actividad; eliminates hours of manual clearing efforts and associated safety risks.

HEAVYDUTY Spiral Bevel Gear & Piñón | Base técnica: Forged alloy steel gears with computeroptimized tooth profile | Beneficio operativo: Transmits high torque smoothly with minimal noise and vibration, even under uneven loading conditions | Impacto del retorno de la inversión: Industry testing demonstrates a typical service life extension of 25% over standard gear sets under comparable duty cycles.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Promedio estándar de la industria | Custom Gyratory Crusher Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad (Tiempo de ejecución programado) | 9294% | 96.5%+ | +35% |
| Tiempo de cambio de revestimiento (Horas) | 2436 horas | 1620 horas | ~40% más rápido |
| Consumo de energía (kWh/t) Baseline Ore| 0.8 1.2 kWh/t| 0.65 0.9 kWh/t| Arriba a 20% Más eficiente |
| Tiempo medio entre fallos (MTBF) Eccentric System| ~12,000 hrs| >18,000 horas| +50% Fiabilidad |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Modelos configurables desde 2,000 tph a más 10,000 tph.
Apertura de alimentación: De 1,070 milímetros (42") arriba a 1,520 milímetros (60") depende del modelo.
Requisito de potencia del motor: Típicamente 375 kW a 750 kilovatios (500 HP a 1000 HP+), suministrado en 6.6 kV or as required.
Peso Total: Ranges from approximately 150 toneladas a más 400 toneladas para configuraciones más grandes.
Especificaciones clave de materiales:
Marco principal & Carcasa superior: Highstrength fabricated steel with stressrelieving treatment.
Mainshaft: Forged from highalloy nickelchromiummolybdenum steel.
Cóncavo & Revestimientos de manto: Aleaciones de acero al manganeso. (14%18% Minnesota), optional chromewhite iron or composite alloys for specific abrasion/corrosion applications.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 40°C a +50°C. Dust seals rated for harsh environments; Sistemas de calefacción/refrigeración opcionales disponibles.

6. ESCENARIOS DE APLICACIÓN

Expansión de mina de cobre a gran escala

Desafío: A planned expansion required a primary crusher capable of handling an additional 8 million tonnes per annum of highly abrasive porphyry ore without increasing footprint or headcount disproportionately.
Solución: Installation of one Custom Gyratory Crusher with INTEGRAL™ liners configured for coarse crushing ahead of SAG mills.
Resultados: Se logró un rendimiento sostenido de 4,500 tph at a consistent P80 of 150mm. La vida útil del revestimiento aumentó en un promedio de 15%, contributing to a calculated total cost per tonne reduction of approximately $0.12 across the crushing circuit.

Cantera de Granito de Alta Producción

Desafío: Frequent downtime due to tramp metal events causing damage and lengthy cavity clearing procedures was limiting annual output targets.
Solución: Implementation of our gyratory crusher equipped with the HYDROSET® PLUS system and SMARTSENSE™ monitoring.
Resultados: Cavity clearing events reduced from an average operational delay of 8 horas a menos 45 minutes per incident. Annual plant availability increased by over 300 horas (12+ días), directly translating to an additional ~450k tonnes crushed per year within existing shifts.

7 CONSIDERACIONES COMERCIALES

Equipment pricing is structured into three primary tiers based on size/capacity (CGC50 Series, CGC60 Series, CGC72 Series) with base configurations including core drive system controls motor starter lubrication unit

Las características opcionales incluyen:
Advanced automation packages remote diagnostic telemetry special alloy liner packages dust suppression ring

Los paquetes de servicios se ofrecen por separado.:
Bronce (Garantía básica) Plata (Planned Inspection & Parts Discount) Oro (FullService Contract including scheduled labor parts predictive monitoring)

Financing options are available through our partners including capital lease operating lease project financing terms typically structured over years

Preguntas frecuentes

¿Cuál es el cronograma típico de instalación??
From delivery onsite mechanical erection electrical connection commissioning full operation typically requires weeks depending on foundation readiness site support

How does this crusher integrate with my existing control system?
The crushers PLC is designed for interoperability providing standard communication protocols Modbus TCP/IP Profibus We supply full interface documentation

Can you provide wear part cost guarantees?
Yes we offer guaranteed maximum wear part cost per tonne contracts based on your specific feed material analysis providing predictable longterm budgeting

¿Cuáles son sus condiciones de pago??
Standard commercial terms involve progress payments tied key milestones delivery acceptance Final payment due upon successful completion performance run

¿Ofrecen capacitación para operadores??
Comprehensive training is included covering safe operation routine maintenance troubleshooting conducted both at commissioning at your facility