1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

La gestión de un circuito de trituración de mineral de hierro presenta distintas, desafíos costosos. 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? Además, does the total cost of ownership for your primary crushing stage—factoring in energy consumption, reemplazos de revestimiento, and labor—exceed initial projections? These operational hurdles directly impact profitability. La pregunta central para los gerentes de planta es esta: ¿Cómo puedes lograr confiabilidad?, hightonnage reduction of abrasive iron ore while controlling operational costs and maximizing plant availability?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

Este producto es un trituradora giratoria primaria engineered specifically for highcapacity iron ore processing. It is designed as the first critical stage in a mineral processing plant, receiving runofmine (memoria de sólo lectura) feed directly from the pit.

Flujo de trabajo operativo:
1. Consumo de alimento: mineral de hierro ROM (hasta 1,5 m de tamaño de trozo) is dumped into the crusher’s deep, tolva receptora sin asfixia.
2. Acción aplastante: A centrally mounted mantle gyrates within a concave bowl, applying compressive force to break the ore against itself.
3. Descargar: 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.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal for largescale mining operations with high daily tonnage requirements (>10,000 MTD). Adecuado para procesamiento duro, abrasive hematite and magnetite ores.
Limitaciones: Not designed for final product sizing or for processing materials with high clay or moisture content without adequate prescreening/scalping. Requiere una base de hormigón estable y un espacio libre importante para la instalación y el mantenimiento..

3. CARACTERÍSTICAS PRINCIPALES

Diseño cóncavo patentado | Base técnica: Segmentario, reversible alloy steel segments | Beneficio operativo: Extiende la vida útil hasta 30% by allowing rotation and use of multiple wear surfaces before replacement | Impacto del retorno de la inversión: Reduces liner inventory costs and downtime for concave changes

Regulación de configuración automática integrada | Base técnica: Sistema de ajuste hidráulico con sensores de posición. | Beneficio operativo: Allows operators to adjust the crusher discharge setting in minutes without stopping the process | Impacto del retorno de la inversión: Maintains optimal product size for downstream efficiency, increasing overall circuit throughput by an estimated 25%

Sistema de lubricación con monitoreo de condición | Base técnica: Dualcircuit filtration and temperature/pressure sensors feeding to plant DCS | Beneficio operativo: Provides continuous protection of critical bearings; alerts personnel to potential issues before failure occurs | Impacto del retorno de la inversión: Prevents catastrophic bearing damage, a failure that can result in over 200 horas de producción perdida

SpiderMounted Dump Hopper & Seal | Base técnica: Reinforced design with multistage dust seal system | Beneficio operativo: Effectively contains dust at the feed point and prevents contaminant ingress into the main bearing assembly | Impacto del retorno de la inversión: Reduces environmental emissions compliance costs and extends bearing life in dusty conditions

Diseño de eje principal de servicio pesado | Base técnica: Forged alloy steel shaft with optimized fatigue resistance profile | Beneficio operativo: Provides exceptional strength to handle tramp steel and uncrushable material events without shaft deflection or failure | Impacto del retorno de la inversión: Eliminates unplanned outages related to shaft failure, a primary cause of extended downtime in primary crushing

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Promedios de la competencia) | This Primary Gyratory Crusher Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad (Tiempo de ejecución programado) | 9294% | 96%+ documented field average over 24 meses | ~34% de mejora |
| Vida del revestimiento (Million Tons/Set) Hematite Ore| 4.5 5.5 toneladas | 6.0 7.0 toneladas verified at multiple sites| ~1520% de mejora |
| Consumo de energía específico (kWh/tonelada) | 0.18 0.22 kWh/t | 0.15 0.17 kWh/t based on installed motor vs. throughput data| ~18% de mejora |
| Tramp Iron PassThrough Recovery Time| limpieza manual; horas de inactividad| Hydraulic clearing system; 80% reduction in event duration |

5. ESPECIFICACIONES TÉCNICAS

Designación del modelo: PGC60110
Apertura de alimentación: 1,520 milímetros (60 pulgadas)
Rango de capacidad nominal: 3,500 7,500 mtph (dependent on ore characteristics and discharge setting)
Potencia instalada: 600 kilovatios (800 caballos de fuerza) electric drive motor
Eje principal: Forged ES355 alloy steel
Cóncavo & Mantle Material: ASTM A128 Manganese Steel with proprietary heat treatment
Peso Total (Solo trituradora): ~275 metric tons
Top Shell Diameter: ~4.8 meters
Rango de temperatura de funcionamiento: 30°C a +45°C (with appropriate lube oil specifications)
Control de polvo: Integral connection points for plant dust extraction system.

6. ESCENARIOS DE APLICACIÓN

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.

Solución:

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

Resultados:

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.

Solución:

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

Resultados:

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 CONSIDERACIONES COMERCIALES

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

Niveles de precios de equipos: Pricing is based on configuration.
Configuración básica: Core crusher assembly with standard lubrication unit.
Configuración avanzada: Includes automatic setting regulation (ASR), sensores avanzados de monitoreo de condición, and upgraded dust sealing.
Turnkey SkidMounted Unit: Crusher preassembled on a structural skid base with walkways, escaleras, and integrated lubrication system for faster installation.

Características opcionales & Actualizaciones: 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.

Paquetes de servicios:
Acuerdo de mantenimiento planificado: Inspecciones programadas, oil analysis programs, y soporte técnico.
Liner Service Contract: Guaranteed liner life performance with fixedcostperton replacement parts.
Contrato de servicio completo: Cubre todas las partes (tener puesto & mecánico), mano de obra, and field service engineering for a fixed annual fee.

Opciones de financiación: 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 Preguntas frecuentes

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