1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Are you facing escalating operational costs and unpredictable availability in your primary crushing circuit? Key challenges with primary gyratory crushers often include:
Tiempo de inactividad no programado: Frequent mechanical failures or liner changes that halt upstream mining and downstream processing, costando miles por hora en producción perdida.
Altos costos de mantenimiento: Excessive consumption of wear parts, complex lubrication system issues, and laborintensive servicing that strain maintenance budgets.
Rendimiento inconsistente: Inability to maintain optimal cavity levels and power draw, leading to bottlenecks and failing to meet designed plant capacity.
Rising Energy Expenditure: Más viejo, inefficient crusher designs consume disproportionate power per ton of processed material, impactando directamente su resultado final.

Is your current primary crusher a reliable asset or a constant source of risk? The solution lies in selecting a modern OEM gyratory crusher engineered for total cost of ownership.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

The OEM Gyratory Crusher is a heavyduty, primary compression crusher designed for the first stage of reducing runofmine ore to a manageable size for conveying and further processing. Its core operational workflow involves:
1. Consumo de alimento: Large feed material is directed into the crushing chamber from the top.
2. Trituración compresiva: A mantle gyrates within a concave bowl, applying compressive force to reduce material by squeezing it against the stationary concaves.
3. Progressive Discharge: Crushed material gravitates downward through the narrowing chamber until it reaches the desired size and exits at the bottom.

This equipment is specifically scoped for hightonnage, minería de roca dura (cobre, mineral de hierro, oro) and largescale aggregate quarrying applications. It is not suited for abrasive recycling materials without specific alloy options or for operations requiring highly portable equipment.

3. CARACTERÍSTICAS PRINCIPALES

Diseño de araña patentado | Base técnica: Onepiece cast alloy steel construction with top shell integration | Beneficio operativo: Eliminates bolton spider arms, reducing stress points and potential for cracking under extreme load | Impacto del retorno de la inversión: Arriba a 40% longer service life on upper assembly components, reducing major rebuild frequency.

Intelligent Lube System (ILS) | Base técnica: Automatizado, dualcircuit lubrication with realtime pressure/temperature monitoring and filtration | Beneficio operativo: Ensures optimal bearing protection under all loads; alerta a los operadores sobre posibles problemas antes de que se produzca una falla | Impacto del retorno de la inversión: Proven to extend bearing life by over 30% and prevent catastrophic luberelated downtime events.

STLF (StraightTaperLowerFlat) Concave Profile | Base técnica: Optimized chamber geometry derived from crushability testing data | Beneficio operativo: Maintains consistent feed opening characteristics throughout liner life for stable throughput and product gradation | Impacto del retorno de la inversión: Entrega hasta 15% more crushed tonnage per concave liner set compared to traditional profiles.

Marco tubular & Mainshaft Design | Base técnica: Forged highstrength steel mainshaft supported within a rigid, onepiece tubular frame | Beneficio operativo: Provides exceptional alignment stability and resists fatigue under cyclical loading for consistent operation | Impacto del retorno de la inversión: Minimizes deflectionrelated wear on bushings and liners, Reducir los costos de mantenimiento a largo plazo..

Integrated Control System (ICS) Interfaz | Base técnica: Standardized PLC platform with MODBUS/J1939 protocols for plantwide integration | Beneficio operativo: Your operators gain realtime control over CSS (Configuración del lado cerrado), consumo de energía, and lubrication from the central control room | Impacto del retorno de la inversión: Enables precise process optimization for energy savings and target product size.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Punto de referencia estándar de la industria | OEM Gyratory Crusher Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad (Programado) | 92 94% | 96%+ (with ILS & Patented Spider) | +24% |
| Toneladas por MWh (Eficiencia Energética) Línea de base = 100%| 100% Reference| 115 118%| +1518% |
| Tiempo de cambio de revestimiento (Conjunto mayor) Average = ~48 hrs| ~48 horas| ~36 horas| 25% |
| Consumo de piezas de desgaste (g/ton crushed) Material Dependent Baseline = 100%| 100% Reference| ~8590%| 10 a 15% |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: dependiente del modelo, de 2,000 tph a más 10,000 tph.
Potencia del motor: Normalmente entre 450 kilovatios y 1,200 kilovatios (600 caballos de fuerza 1,600 caballos de fuerza), adaptado al deber.
Apertura de alimentación: Tamaños de apertura desde 1,000 mm a 1,500 milímetros (39" a 59").
Especificaciones clave de materiales:
Marco principal & Carcasa superior: Acero fundido de alta resistencia.
Manto & Cóncavo: Aleaciones de acero al manganeso.; optional premium alloys for specific abrasion/corrosion applications available.
Mainshaft: Forged highstrength alloy steel.
Dimensiones físicas: Huella significativa; exact L x W x H varies by model. Requires engineered reinforced concrete foundation.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 40°C a +50°C (40°F a +122°F). Dust seals rated for harsh environments.

6. ESCENARIOS DE APLICACIÓN

Expansión de mina de cobre a gran escala

Desafío: An existing mine’s expansion required a new primary crushing station capable of handling an additional 12 million tpy of sulfide ore while operating at >95% availability in a remote location with high service costs.
Solución: Installation of a single largecapacity OEM Gyratory Crusher with the Intelligent Lube System (ILS) and remote monitoring capabilities.
Resultados: Se logró el rendimiento del diseño dentro de los tres meses posteriores a la puesta en servicio.. The ILS prevented two potential bearing failures in the first two years as flagged by its monitoring system. Disponibilidad promediada 96.7% over three years.

HighAbrasion Granite Quarry

Challenge A major aggregate producer faced unsustainable wear part costs and excessive downtime due to biweekly concave changes in their primary crushing stage.
Solution Replacement with an OEM Gyratory Crusher featuring the STLF concave profile and optional ultrawearresistant alloy liners specified for granite.
Results Liner service life increased from an average of 14 días para 21 días. This reduced annual scheduled liner change downtime by approximately 120 horas, while also lowering liner cost per ton by an estimated 18%.

7. CONSIDERACIONES COMERCIALES

OEM Gyratory Crushers are capital investments priced according to size, capacity specifications (<tph), selected metallurgy options (<alloy grade), nivel de automatización (<control package). Pricing typically falls into distinct tiers based on inlet size (<42", <54", <60”+).

Optional features that affect final pricing include:
Regulación de configuración automatizada () sistema
Premium alloy packages for mantles/concaves
Sensores de monitoreo de condición avanzados (, temperatura)
Extended factory warranty packages

Comprehensive service agreements are available covering planned maintenance inspections parts supply (, aspectos), technical support These agreements can be structured as fixedcost annual contracts providing budget certainty Financing options including leasing capital equipment loans are offered through certified partners

8. Preguntas frecuentes

Q What are the lead times typically involved?
A Lead times vary based on model complexity current manufacturing capacity but generally range from

Q Can this crusher integrate with our existing PLC control system?
A Yes The Integrated Control System uses industrystandard communication protocols like MODBUS TCP/IP ensuring compatibility with most modern plant DCS systems

Q How does this design improve safety during maintenance?
A Key safety features include hydraulic setting adjustment eliminating manual work under tension integrated lifting points designed rigging procedures provided

Q What is included in standard commissioning?
A Standard commissioning includes field assembly supervision initial startup performance testing operator training Documentation includes detailed installation maintenance manuals

P ¿Se proporcionan garantías de desempeño??
A Yes performance guarantees covering throughput power consumption product gradation are contractually defined based on agreed feed material characteristics