1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y la disponibilidad impredecible están erosionando la rentabilidad de su circuito de trituración primario?? Para gerentes de planta y contratistas de ingeniería, La etapa de trituración primaria es un cuello de botella crítico donde las ineficiencias se propagan en cascada a lo largo de toda la línea de procesamiento.. Los desafíos comunes incluyen:
Tiempo de inactividad excesivo para cambios de revestimiento: Las paradas de mantenimiento tradicionales para el reemplazo del manto y el cóncavo pueden detener la producción durante 2472 horas, costando decenas de miles en rendimiento perdido.
Paros no planificados por Tramp Iron: Inadequate protection from noncrushable material leads to costly damage, requiring immediate intervention and component replacement.
Alimentación inconsistente & Distribución del tamaño del producto: Fluctuating feed material characteristics cause chokefeeding issues or cavity flooding, reducing throughput and increasing power consumption per ton.
Alta operativa & Maintenance Labor Costs: Ajustes manuales frecuentes, lubrication system monitoring, and component wear inspections demand significant skilled labor hours.

Is your operation seeking a primary crusher solution engineered to deliver maximum uptime, menor costo por tonelada, and predictable performance in the face of these challenges?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

A trituradora giratoria es un trabajo pesado, continuousduty primary crushing machine designed for highcapacity applications in largescale mining and aggregate operations. Its core mechanism involves a gyrating mantle within a stationary concave, creating a progressive crushing cavity that reduces runofmine ore or shot rock to a manageable size for downstream conveying and processing.

Flujo de trabajo operativo:
1. Consumo de alimento: Largesized material is directed into the top of the crusher via dump trucks, cargadores, or a shovel.
2. Trituración progresiva: The eccentrically driven mantle gyrates within the concave, applying compressive force to reduce material size with each cycle.
3. Descargar: El producto triturado sale por el fondo de la cámara de trituración. (la abertura de descarga) onto a conveyor belt for transport to the next stage.

Ámbito de aplicación: Ideal para alto tonelaje (1,500+ TPH) minería de roca dura (cobre, mineral de hierro, oro), grandes operaciones de cantera, and major industrial mineral processing plants requiring primary reduction of abrasive materials.

Limitaciones: No apto para operaciones de baja capacidad. (<500 TPH) debido al alto costo de capital. Requires significant foundational support and vertical height. Less effective for recycling or asphalt crushing where jaw crushers or impactors may be preferred.

3. CARACTERÍSTICAS PRINCIPALES

Diseño de araña patentado | Base técnica: multibrazo, forged alloy steel construction with top shell attachment | Beneficio operativo: Distributes load evenly across the main shaft and bearings, providing exceptional stability under shock loading from large feed material | Impacto del retorno de la inversión: Extiende la vida útil del rodamiento hasta 40%, reducing major overhaul frequency and associated downtime costs.

Regulación de configuración automática integrada (ASR) Sistema | Base técnica: Ajuste hidráulico con sensores de posición en tiempo real. | Beneficio operativo: Allows operators to adjust the crusher discharge setting remotely in minutes without stopping production, optimizing product size for changing downstream requirements | Impacto del retorno de la inversión: Maintains optimal throughput and circuit efficiency; elimina 48 hours of manual adjustment labor per change.

Sistema de lubricación con enfriadores dobles & Filtración | Base técnica: Highflow circulation with temperature control and particulate filtration | Beneficio operativo: Ensures consistent bearing temperature under peak loads; removes metallic wear particles from oil | Impacto del retorno de la inversión: Prevents thermalrelated bearing failures; Los datos de campo muestran una 25% reduction in lube oil degradation rate, reduciendo los costos de consumibles.

Manganese Steel Concave & Revestimientos de manto | Base técnica: Workhardening austenitic manganese steel castings | Beneficio operativo: Liners develop a hardened surface layer during operation that resists abrasion while maintaining core toughness against impact fractures | Impacto del retorno de la inversión: Achieves industryleading wear life (measured in tons crushed), directly lowering costperton for wear components.

Tramp Iron Relief System | Base técnica: Hydraulic cylinders support the main shaft assembly; pressure sensors detect uncrushable objects | Beneficio operativo: Automatically opens the discharge setting to release tramp iron, then returns to original setting without stopping the crusher drive motor | Impacto del retorno de la inversión: Previene daños catastróficos; avoids unplanned downtime events that can exceed $100k in lost production per incident.

Chamber Profile Optimization | Base técnica: Computermodeled nonchoking concave design with optimized nip angle | Beneficio operativo: Promotes firstpass reduction at the top of the chamber and ensures steady material flow without bridging or erratic power draw | Impacto del retorno de la inversión: Entrega hasta 10% higher throughput compared to conventional profiles with identical motor power input.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Industry Standard Gyratory Crusher | Nuestra solución de trituradora giratoria | Ventaja (% mejora) |
| : | : | : | : |
| Disponibilidad (Programado) | 9294% availability factor due to liner change downtime| 96%+ availability factor via quickchange liner systems & ASR| +34% Más horas productivas anualmente. |
| Consumo de energía específico| ~0.8 1.0 kWh/tonelada triturada| ~0,7 0.85 kWh/tonne crushed via optimized kinematics| Arriba a 15% lower energy cost per ton |
| Wear Life Concaves (mineral abrasivo)| Life measured relative to baseline = 100%| Life measured relative to baseline = 130150%| +3050% intervalos de servicio más largos |
| Es hora de ajustar CSS| Manual adjustment requires 48 hour shutdown| Remote hydraulic adjustment in <15 minutes via ASR system| ~98% less downtime for adjustments |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 1,500 a más 12,000 toneladas por hora (TPH), dependiendo del tamaño del modelo y del material de alimentación.
Potencia del motor: Electric drive motors ranging from 450 kW a más 1 megavatio (600 1,300 caballos de fuerza).
Apertura de alimentación: Tamaños de apertura desde 1,000 mm hasta 1,800 milímetros (aprox. 40" a 72").
Rango de ajuste de configuración de descarga: normalmente de 125 mm a 250 milímetros (5" to10"), adjustable via hydraulic system.
Marco principal & Shell Material: Fabricated from hightensile strength steel plate; critical areas feature wearresistant liners.
Main Shaft Material: Forged from highstrength alloy steel with precision machining.
Rango de temperatura de funcionamiento: Designed for ambient conditions from 40°C to +50°C (40°F a +122°F). Lube system includes heaters/coolers as required.
Contención de polvo: Standard flanges provided for integration with dry dust suppression systems or water spray systems.

6. ESCENARIOS DE APLICACIÓN

Expansión de mina de cobre a gran escala

Desafío: A Tier1 copper operation needed to increase primary crushing capacity by over 30% within existing footprint constraints while managing highly abrasive sulfide ore that caused rapid liner wear.
Solución: Implementation of two highcapacity Gyratory Crushers featuring our optimized chamber profile and premium manganese liners.
Resultados: Se logró un rendimiento sostenido de 8 ,500 TPH per crusher. La vida útil del revestimiento aumentó en 35%, extending changeout cycles from 6 meses a más 8 meses. Overall plant availability improved by 2 .5%.

Major Granite Quarry Complex

Desafío: Unpredictable feed blockiness led to frequent cavity choking events in existing primary crushers , causing circuit stoppages , excessive energy spikes , and premature component stress .
Solución : Installation of a single heavyduty Gyratory Crusher equipped with an advanced nonchoking concave design and an automated tramp iron relief system .
Resultados : Eliminated unplanned choking events . Power draw stabilized , reducing specific energy consumption by 12%. Production yield of spec base material increased due t o more consistent product gradation .

7 . CONSIDERACIONES COMERCIALES

Pricing tiers are structured according t o crusher size , capacidad ,and optional feature packages :
Base Model Range : Includes core crusher assembly , standard lubrication unit ,e instrumentación básica . Suitable f or standard duty cycles .
Paquete de rendimiento : Adds Integrated ASR system , sensores avanzados de monitoreo de condición ,and quickchange liner kits . Recommended f or operations prioritizing flexibility .
Premium Service Package : Bundles equipment with extended warranty coverage , predictive maintenance analytics software subscription,and guaranteed OEM spare parts delivery terms .

Financing Options include capital purchase ,contratos de arrendamiento operativo,and throughputbased contracts where payments correlate directly w ith achieved production volume .

Service Packages range f rom basic technical support t o comprehensive onsite maintenance contracts managed b y factorytrained technicians .

8 . Preguntas frecuentes

q : Can this gyratory crusher replace our existing primary jaw crusher without major modifications t o th e feed arrangement ?
A : While possible,the taller vertical profile typically requires reassessment o f dump pocket design an d feeder height .Our engineering team provides detailed layout studies t o evaluate retrofit feasibility .

q : What i s th e typical installation an d commissioning timeline ?
A From delivery t o first ore,a standard project requires 8 12 semanas,following foundation readiness.This includes mechanical erection,lubrication an d hydraulic system commissioning,motor alignment,and noload/load testing .

Q How does th e automatic setting regulation impact final product shape ?
A The ASR adjusts th e closed side setting(CSS )t o control top size.It does not alter th e fundamental compressive breakage action,s o product shape(Cubicidad )remains consistent w ith gyratory crushing characteristics .

Q Are wear parts interchangeable w ith other OEM g y r atory crushers ?
A No.Critical wear components like concaves,mantos,and spider arm guards are designed specifically f or our chamber geometry an d mounting systems.They are not dimensionally interchangeable,preserving designed performance an d safety .

Q What training i s provided f or our operations an d maintenance teams ?
A We provide comprehensive onsite training covering safe operation,procedimientos de mantenimiento de rutina,guías de solución de problemas,and specific instruction on using th e ASR an d condition monitoring systems .

Q What i s your lead time f o r critical spare parts ?
A Our global logistics network targets 9 5 % availability f or critical rotating assembly spares exstock fr om regional service centers.Nonstandard parts have defined manufacturing lead times provided upon request .