Folleto de trituradora giratoria que cumple con RoHS
1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR
Are you facing escalating operational costs and unpredictable availability in your primary crushing circuit? Common challenges with traditional gyratory crushers include excessive liner wear leading to frequent maintenance shutdowns, Alto consumo de energía por tonelada de material procesado., and inconsistent product gradation that stresses downstream processes. Estos problemas afectan directamente sus resultados a través del tiempo de inactividad no planificado., rising spare parts inventories, and suboptimal plant throughput.
How can you achieve more tons between maintenance intervals? Is it possible to reduce your energy cost per ton while maintaining precise discharge settings? ¿Qué sería un 20% improvement in crusher availability mean for your annual production targets? The solution requires a fundamental reengineering of the gyratory crusher’s core components and lubrication philosophy.
2. DESCRIPCIÓN GENERAL DEL PRODUCTO
The Rohs Compliant Gyratory Crusher is a primary crushing machine engineered for highcapacity, continuous operation in demanding mining and aggregate applications. It is designed to accept large feed material from haul trucks or loaders and reduce it to a consistent, tamaño transportable para procesamiento secundario.
Flujo de trabajo operativo:
1. Alimentar: Gran runofmine (memoria de sólo lectura) rock is directed into the crushing chamber via a feed hopper.
2. Acción aplastante: A vertically oriented mantle gyrates within a concave bowl, applying compressive force to the rock against the stationary concaves.
3. Descargar: Crushed material gravitates through the narrowing gap at the chamber's bottom, exiting through the discharge opening set by the mainshaft position.
Ámbito de aplicación: Ideal for hightonnage primary crushing stations in hard rock mining (cobre, mineral de hierro, oro), canteras de agregados a gran escala, y operaciones minerales industriales.
Limitaciones: Not suitable for highly abrasive recycling materials without specific liner configurations or for operations requiring extreme portability.
3. CARACTERÍSTICAS PRINCIPALES
Perfil de revestimiento patentado | Base técnica: Optimized crushing chamber geometry based on DEM (Modelado de elementos discretos) | Beneficio operativo: Promueve la trituración entre partículas., reduces wasteful sliding wear on liners, and produces a more cubical product | Impacto del retorno de la inversión: Los datos de campo muestran hasta 30% longer liner life, reducing cost per ton for wear parts.
Sistema de accionamiento de alta eficiencia | Base técnica: Direct gearless drive with variable frequency control (VFC) | Beneficio operativo: Eliminates traditional pinionandgear losses, provides smooth startup under full load, and allows realtime adjustment of crusher stroke | Impacto del retorno de la inversión: Las pruebas de la industria demuestran 1218% lower energy consumption compared to standard geared drives.
Integrated Smart Lubrication | Base técnica: Conditionbased oil filtration and cooling with realtime particle monitoring | Beneficio operativo: Maintains optimal oil cleanliness and temperature, preventing premature bearing failure and viscosity breakdown | Impacto del retorno de la inversión: Extends major lubrication service intervals by 2x, reducing fluid costs and downtime risk.
Sistema de ajuste de configuración automatizado (BÁSICO) | Base técnica: Hydraulic mainshaft positioning with digital feedback sensors | Beneficio operativo: Allows remote or automated adjustment of the closedside setting (CSS) for consistent product size without stopping the crusher | Impacto del retorno de la inversión: Improves overall plant consistency; eliminates manual adjustment downtime.
Robust Spider Design | Base técnica: Forged alloy steel construction with optimized ribbing for stress distribution | Beneficio operativo: Provides maximum stability for the top bearing assembly under shock loads from uncrushable material | Impacto del retorno de la inversión: Minimizes risk of catastrophic structural damage, protegiendo el valor de sus activos a largo plazo.
EcoGard Sealing System | Base técnica: Multistage labyrinth seals with positivepressure air purge | Beneficio operativo: Effectively excludes dust from the eccentric bushing and drive system while retaining lubricant | Impacto del retorno de la inversión: Dramatically increases component life in dusty environments; reduces seal replacement frequency.
4. VENTAJAS COMPETITIVAS
| Métrica de rendimiento | Estándar de la industria | Rohs Compliant Gyratory Solution | Ventaja (% mejora) |
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| Vida del revestimiento (mineral abrasivo) | 450,000 550,000 montones | 650,000 700,000 montones | +20% |
| Consumo de energía | 0.85 1.0 kWh/t | 0.72 0.80 kWh/t | 15% |
| Disponibilidad | 92 94% | 95 96% | +3 Puntos porcentuales |
| Tiempo de ajuste de CSS | Manual process (48 hours downtime)
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| Oil Change Interval
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5. ESPECIFICACIONES TÉCNICAS
Rango de capacidad: dependiente del modelo; de 2,500 a más 10,000 toneladas métricas por hora.
Requisitos de energía: De 450 kW hasta 800 kW motor de accionamiento principal; VFC compatible.
Especificaciones de materiales: Marco principal & concaves available in various manganese steel alloys; Shaft in highstrength forged steel; Bronze bushings with leadfree alternatives.
Dimensiones físicas: Significant footprint savings versus older designs; specific dimensions provided per model quotation.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 25°C a +50°C (13°F a +122°F). Dust protection rating IP66 standard.
Cumplimiento: Manufactured in accordance with Rohs directives restricting hazardous substances in electrical components.
6. ESCENARIOS DE APLICACIÓN
Ampliación de la mina de cobre
Desafío: Se necesitaba una importante operación de cobre para aumentar el rendimiento de trituración primaria en 25% sin ampliar el espacio de su trituradora primaria ni sobrecargar los transportadores existentes.
Solución: Implementation of a Rohs Compliant Gyratory Crusher with the HighEfficiency Drive System and optimized liner profile.
Resultados: Logró un 28% throughput increase at a finer target product size due to higher reduction efficiency. Energy use per ton decreased by an average of 14%, meeting expansion goals within existing infrastructure constraints.
Cantera de agregado de granito
Desafío: Unpredictable liner wear led to variable product gradation and frequent production stoppages for mantle changes every six weeks.
Solución: Installation of a midsize Rohs Compliant Gyratory Crusher featuring the Patented Liner Profile and Automated Setting Adjustment System.
Resultados: Liner life extended consistently to nine weeks while maintaining tighter control on topsize product through remote CSS adjustments during shifts. This resulted in an annual increase of over two weeks of productive runtime.
7. CONSIDERACIONES COMERCIALES
The Rohs Compliant Gyratory Crusher is offered across three primary capacity tiers—HighProduction (>8k tph), StandardDuty (48k tph), and CompactPrimary (<4k tph)—with pricing structured accordingly based on specifications.
Características opcionales: Advanced predictive health monitoring sensors (vibración/temperatura), automated tramp iron clearing systems,
spare mainshaft assemblies for rapid changeout programs.
Paquetes de servicios: Tiered plans are available from basic preventive maintenance support up to fullsite performance guarantees including parts coverage and dedicated onsite technical support.
Opciones de financiación: Flexible capital equipment financing can be arranged through our partners,
including leasetoown structures that align payments with projected production revenue streams,
helping manage cash flow during capitalintensive projects.
8. Preguntas frecuentes
Q1. Is this gyratory crusher compatible with my existing secondary/tertiary circuit?
Our engineering team conducts full circuit analysis using your current equipment data
to ensure optimal feed size distribution compatibility before any recommendation is made
Q2. ¿Cuál es el cronograma típico de instalación desde la entrega hasta la puesta en servicio??
Para un sitio totalmente nuevo,
allow approximately four months from foundation work through mechanical erection,
electrical tieins,
y puesta en marcha
Brownfield replacements can often be completed faster using preengineered transition plans
Q3. How does this design specifically address maintenance labor costs?
Features like remote setting adjustment,
centralized lube points,
and modular spider/bowl assemblies are engineered specifically
to reduce both timeontool
and required crew size for routine tasks
Q4. Are there financing options that separate machine cost from service packages?
Sí
Capital equipment financing
and operational service agreements are structured separately
This allows you greater flexibility in budgeting capital expenditure versus operational expenditure
Q5. Qué capacitación se brinda a nuestro equipo de operaciones?
We provide comprehensive operator training focused on daily checks,
the ASAS system,
and basic troubleshooting along with detailed maintenance manuals
for your technical staff
Q6. Can you guarantee performance metrics like throughput or liner life?
Performance guarantees are offered as part of our premium service packages
These are based on agreedupon feed material characteristics
and are contractually defined prior to purchase
P7. How does Rohs compliance affect longterm parts availability?
Rohs compliance ensures all electrical components will remain globally procurable as environmental regulations tighten It futureproofs your investment against supply chain restrictions