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?? Los gerentes de planta y los contratistas de ingeniería enfrentan constantemente desafíos críticos con sus trituradoras giratorias primarias., incluido:

Tiempo de inactividad excesivo para mantenimiento: Los diseños tradicionales requieren mucho tiempo., complex procedures for wear part replacement and chamber clearing, leading to production losses that can exceed 100 horas al año.
Paros no planificados por Tramp Iron: Noncrushable material entering the chamber can cause significant damage, resulting in catastrophic component failure, emergency shutdowns, and sixfigure repair bills.
Rendimiento inconsistente & Tamaño del producto: Worn or poorly configured crushers fail to maintain target product gradation, causing bottlenecks in downstream processes and reducing overall plant efficiency by 515%.
Alta operativa & Costos de energía: Inefficient crushing chambers and highfriction components lead to specific energy consumption (kWh/tonelada) figures that directly impact your bottom line.

¿Es su trituradora primaria actual un activo confiable o una fuente recurrente de costos y demoras?? La solución radica en seleccionar una trituradora giratoria diseñada no solo por su capacidad., pero para un control total de los costos operativos.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO: TRITURADORA GIRATORIA

Una trituradora giratoria es una máquina trituradora de compresión estacionaria fundamental para operaciones mineras y de agregados de alto tonelaje.. It is designed for primary crushing of runofmine ore or blasted quarry rock into a size suitable for secondary processing.

Flujo de trabajo operativo:
1. Consumo de alimento: Material de alimentación grande (hasta 1,5 m de tamaño) is delivered via haul trucks or loaders into the topmounted feed hopper.
2. Trituración compresiva: The central mantle gyrates within the concave liners, applying progressive compressive force to reduce material by pinching and bending.
3. Descargar: El producto triturado sale a través de la abertura de descarga en el fondo de la cámara de trituración., its size determined by the closedside setting (CSS).

Ámbito de aplicación & Limitaciones:
Alcance: Ideal para alta capacidad (1,000 10,000+ tph) aplicaciones de trituracion primaria en la mineria de roca dura (mineral de hierro, cobre, oro), canteras de agregados a gran escala, y procesamiento industrial de minerales.
Limitaciones: Not suitable for abrasive recycling materials with high metal content. Requiere una base de hormigón estable y un espacio vertical significativo para la instalación.. Lower initial mobility compared to mobile jaw crusher setups.

3. CARACTERÍSTICAS PRINCIPALES

Cóncavo patentado & Perfiles de manto | Base técnica: Computeroptimized chamber geometry based on DEM (Modelado de elementos discretos) | Beneficio operativo: Delivers consistent product gradation throughout the liner life with reduced risk of bridging | Impacto del retorno de la inversión: Maintains downstream circuit efficiency, improving overall plant yield by an estimated 38%.

Sistema integrado de liberación automática de residuos | Base técnica: Hydraulic cylinders support the mainshaft; pressure sensors detect uncrushable material | Beneficio operativo: Automatically lowers the mainshaft to pass tramp iron, then resumes position without stopping | Impacto del retorno de la inversión: Prevents damageinduced downtime; field data shows a reduction of over 90% in tramp ironrelated stoppages.

Diseño de servicio superior (TSD) | Base técnica: All major service components accessible from above via a central service platform | Beneficio operativo: Enires concaves and mantles can be replaced in 4872 horas versus 710 days with traditional designs | Impacto del retorno de la inversión: Reduces planned maintenance downtime by approximately 70%, translating to thousands of additional production hours over the crusher's life.

Estructura principal de acero de aleación de alta resistencia & Excéntrico | Base técnica: Forged from highintegrity alloy steel with finite element analysis (FEA) validation | Beneficio operativo: Provides exceptional durability under extreme cyclical loading with minimal deformation | Impacto del retorno de la inversión: Extiende la vida útil estructural más allá 30 años, protegiendo su inversión de capital a largo plazo.

Transmisión directa & Variable Speed Capability | Base técnica: Lowspeed synchronous motor connected directly to the eccentric via a coupling | Beneficio operativo: Elimina el mantenimiento de la correa trapezoidal; variable speed allows optimization of throughput and product shape for different feed materials | Impacto del retorno de la inversión: Increases energy transmission efficiency by up to 5% versus traditional drives and provides operational flexibility.

Sistema de lubricación automatizado centralizado | Base técnica: Programmable system delivering precise oil volume and pressure to all critical bearings | Beneficio operativo: Garantiza una temperatura y salud óptimas del rodamiento., providing early warning diagnostics | Impacto del retorno de la inversión: Extends bearing lifecycles by up to 40% and prevents costly bearing failures.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Punto de referencia estándar de la industria | Nuestra solución de trituradora giratoria | Ventaja documentada |
| : | : | : | : |
| Disponibilidad (Anual) | 92 94% | 96%+| >2% mejora |
| Consumo de energía específico| Varía según el mineral; línea de base = 100%| 9095% de línea base| 510% reduction in kWh/tonne |
| Tiempo de cambio de revestimiento (Conjunto completo) | 7 10 días| 2 3 días| ~70% más rápido |
| Tiempo medio entre fallos (MTBF) Componentes principales| Industry average established| +35% longer MTBF| Significant reduction in unplanned events |
| Consistencia del rendimiento (Liner Life Variance)| +/15% from newtoworn| +/8% from newtoworn| More stable feed for downstream processes |

5. ESPECIFICACIONES TÉCNICAS

Gama de modelos & Capacidad: Available in multiple sizes with rated capacities from 1,200 a más 12,000 toneladas por hora, based on standard crushable ore density.
Requisitos de energía: Clasificaciones del motor de accionamiento de 300 kW hasta 1,200 kilovatios, dependent on model and application. Electrical supply must match motor specifications.
Especificaciones de materiales: Mainframe constructed from hightensile carbon steel plate. Concave and mantle liners available in premium manganese steel alloys or optional composite materials for specific abrasion/impact conditions.
Dimensiones físicas & Peso: Feed opening diameters range from 800mm to 1,500mm. La altura total instalada varía desde 6m to 10m. Machine weights range from 150 a más 450 montones.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 40°C a +50°C. Dust seals are rated for severe environments. Can be equipped with housing heaters or cooling systems as required.

6. ESCENARIOS DE APLICACIÓN

Expansión de mina de cobre a gran escala

Desafío: Se necesitaba una importante operación de cobre para aumentar el rendimiento de la planta en 25%. The existing primary gyratory was a bottleneck with frequent liner changeover delays exceeding one week.
Solución: Implementation of a new highcapacity gyratory crusher featuring TopService Design and optimized chamber profiles.
Resultados: Se logró un rendimiento sostenido de 8,500 tph. Liner changeouts were completed in under three days each cycle. The project met its expansion CAPEX goals with an estimated payback period of under three years based on increased production.

Modernización de canteras de agregados de granito

Desafío: An aging primary crusher led to unpredictable product gradation causing inefficiencies in secondary/tertiary stages and high energy costs per ton.
Solución: Replacement with a modern gyratory crusher equipped with variable speed drive and automated control system interfacing with the plant SCADA.
Resultados: Se mejoró la consistencia del producto, reducing recirculating load in downstream cones by an average of 18%. Overall plant energy consumption per ton of saleable aggregate decreased by 9%.

7. CONSIDERACIONES COMERCIALES

Niveles de precios de equipos:
Configuración básica (Servicio estándar): Includes core crusher assembly drive motor lubrication system basic instrumentation
Premium Configuration Heavy Duty): Includes upgraded liners enhanced automation package advanced condition monitoring sensors extended warranty
Turnkey SkidMounted Solutions Available

Características opcionales:
Advanced predictive maintenance software integration
Special alloy liner packages for highly abrasive ores
Remote diagnostic capability
Automated setting adjustment system

Paquetes de servicios:
1 Bronze Plan): Includes scheduled inspections parts discount
2 Silver Plan): Adds annual preventative maintenance labor coverage
3 Gold Plan): Comprehensive coverage including planned liner changeouts guaranteed response times

Opciones de financiación:
Flexible commercial structures are available including capital purchase finance lease or longterm performancebased crushing contracts tailored project financing

Preguntas frecuentes

¿Cuáles son los requisitos básicos??
A reinforced concrete foundation designed per supplied load drawings is required typically involving several hundred cubic meters concrete Installation must be performed certified contractors

How does this integrate with our existing SAG mill feed conveyor system?
Our engineering team will provide detailed interface drawings belt loading data Our control systems are designed communicate using standard industrial protocols Modbus TCP/IP Profinet

¿Cuál es la vida útil operativa esperada??
The mainframe shell eccentric assembly are designed minimum year lifespan Wear components concaves mantles have service life dependent application typically ranging months several years

Do you offer liner profiling services optimize our specific ore type?
Yes we provide proprietary wear analysis modeling recommend optimal chamber profiles maximize throughput product shape minimize cost per ton crushed This included premium service packages

What are payment terms typical delivery lead time?
Standard terms progress payment milestone Final payment prior shipment Lead times vary model complexity Typically range months order confirmation ex works Expedited options may available