1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Está usted gestionando operaciones de trituración donde la confiabilidad del equipo, gradación consistente del producto, and total cost of ownership directly determine profitability? Para gerentes de planta y contratistas de ingeniería, the challenges with primary crushing are quantifiable. Unplanned downtime for mantle or concave replacement can halt an entire processing line, costando decenas de miles por hora en producción perdida. Inconsistent feed size or moisture content can lead to choking, reducing throughput and increasing power consumption per ton. Además, the global push for responsible manufacturing means sourcing equipment that complies with environmental directives like RoHS is no longer optional but a prerequisite for many projects and tenders.

How do you achieve higher availability with lower maintenance labor? Can your primary crusher deliver a consistent product curve despite variable feed? Are your equipment partners providing verifiable compliance documentation for hazardous substance control? The solution lies in specifying a Trituradora giratoria que cumple con RoHS from a manufacturer committed to both performance and material integrity.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

A Trituradora giratoria que cumple con RoHS is a primary crushing machine designed for highcapacity, continuous operation in largescale mining and aggregate operations, built with strict adherence to the Restriction of Hazardous Substances (RoHS) directiva. This governs the use of specific hazardous materials in electrical components and certain mechanical alloys.

Flujo de trabajo operativo:
1. Consumo de alimento: Large runofmine ore or quarry rock is directly dumped into the crusher’s receiving hopper above the spider assembly.
2. Acción aplastante: The gyrating mantle eccentrically compresses material against the stationary concave liners, applying progressive compressive force to break particles.
3. Descargar: El material triturado cae por gravedad a través del espacio decreciente en el fondo de la cámara y sale por la abertura de descarga..

Ámbito de aplicación: Ideal para alto tonelaje (1,500+ tph) primary crushing stations handling abrasive ores (hierro, cobre, oro) y roca dura. It is the preferred solution for slabby feed material due to its nonchoking design.

Limitaciones: Higher capital cost compared to jaw crushers; requires a substantial and stable foundation due to weight and dynamic forces; no apto para plantas portátiles u operaciones de bajo tonelaje.

3. CARACTERÍSTICAS PRINCIPALES

Patented Liner Profiles | Base técnica: Optimized crushing chamber geometry via DEM (Modelado de elementos discretos) simulación | Beneficio operativo: Achieves targeted product size distribution with up to 10% lower power draw per ton crushed | Impacto del retorno de la inversión: Reduced energy costs and extended liner life through even wear distribution.

Integrated Smart Chamber Relief System | Base técnica: Hydraulicmechanical tramp release and clearing system with realtime pressure monitoring | Beneficio operativo: Automatically discharges uncrushable material and resets in under 60 artículos de segunda clase, preventing damage to mainshaft and bearings | Impacto del retorno de la inversión: Eliminates hours of manual clearing downtime and avoids catastrophic failure repair costs.

RoHSVerified Component Sourcing | Base técnica: Full material declarations from suppliers for electrical systems, sellos, lubricantes, and specified alloys | Beneficio operativo: Ensures global market access, simplifies endoflife recycling, and mitigates supply chain risk related to noncompliant parts | Impacto del retorno de la inversión: Prevents project delays or rejections in regulated regions and futureproofs asset value.

Peripheral Spray System | Base técnica: Programmable logiccontrolled dust suppression nozzles integrated into the base frame | Beneficio operativo: Effectively contains dust at discharge without oversaturating material | Impacto del retorno de la inversión: Mantiene el cumplimiento normativo para las emisiones de partículas., reduce los costos de limpieza, and improves site safety.

Filosofía de diseño TopService | Base técnica: All routine maintenance tasks (cambios de revestimiento, renovación del brazo de araña) accesible desde arriba | Beneficio operativo: Reduces required service time by up to 30% compared to bottomservice designs; enhances safety by keeping personnel out from under suspended loads | Impacto del retorno de la inversión: Increases plant availability and lowers labor costs for planned maintenance events.

HighFidelity Condition Monitoring Ports | Base técnica: Preinstalled sensor ports for vibration, temperatura, y presión sobre los cojinetes y el sistema de lubricación | Beneficio operativo: Enables direct integration with plant PLC/SCADA for predictive maintenance scheduling | Impacto del retorno de la inversión: Transforma el mantenimiento de calendario a condición, optimizing part inventory and preventing unplanned stops.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria | Solución de trituradora giratoria que cumple con RoHS | Ventaja (% mejora) |
| : | : | : | : |
| Tiempo de cambio de revestimiento| 2436 horas (manual jacking & manejo) | 1624 horas (integrated hydraulic assist & topservice)| Arriba a 33% más rápido |
| Consumo de energía específico| Varía según el mineral; baseline established per project kWh/t| Cámara optimizada & drive motor efficiency reduces draw| Documentado 510% reducción |
| Tiempo medio entre fallos (Main Bearing)| ~60,000 operating hours with ideal conditions & lubricación| >75,000 hours via advanced filtration & monitoring integration| >25% aumentar |
| Regulatory Documentation Depth| Certificate of Compliance only| Full material traceability dossier for major assemblies| 100% auditready compliance |
| Dust Emission at Discharge| Reliant on external spray systems often added postinstallation|< 10 mg/m³ with integrated, automated spray system factorytuned to crusher airflow| Meets stringent international standards at commissioning |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 1,500 a más 10,000 toneladas métricas por hora (tph), dependiendo del tamaño del modelo, tamaño de alimentación (F80), y entorno cerrado (CSS).
Requisitos de energía: Motores de accionamiento principal de 300 kW hasta 1 MW+. Supplied for voltages of 6.6kV or 11kV as standard; otros voltajes disponibles.
Especificaciones de materiales: Marco principal: Highstrength fabricated steel ASTM A36/A572. Concave/Mantle Liners: Manganese steel ASTM A128 Grade B2/B3+ or proprietary chromeenhanced alloys. Todos los componentes eléctricos. (<1000V): Certified RoHS compliant.
Dimensiones físicas: Varía significativamente según el modelo.. Ejemplo (Servicio mediano): Total height ~56m; installed weight (including base frame) ~250400 metric tons.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +50°C. Lubrication systems include heater/cooler packages as required. Dust sealing effective in environments with airborne particulate.

6. ESCENARIOS DE APLICACIÓN

Copper Mine Expansion Project – Primary Crushing Circuit

Desafío: An existing SAG mill feed circuit was bottlenecked by an aging primary crusher with frequent liner failures and excessive energy use (~0,85 kWh/t). The project had strict EUderived environmental procurement rules.
Solución: Installation of a new midsize RoHS Compliant Gyratory Crusher featuring smart chamber geometry and highefficiency drives.
Resultados: El rendimiento aumentó en 18% while specific energy consumption dropped to 0.76 kWh/t. The provided full material compliance dossier satisfied the project’s green procurement requirements without delay.

Granite Aggregate Producer – HighAbrasion Quarry

Desafío: Extremely abrasive granite was causing concave liner life of only 4 months in a standard gyratory crusher, leading to high consumable costs and unpredictable downtime.
Solución: Implementation of a heavyduty RoHS Compliant Gyratory Crusher configured with proprietary chromemoly liners and an optimized peripheral spray system to reduce dust without accelerating liner wear.
Resultados: La vida útil del revestimiento se extendió a más de 6 months—a 50% improvement—reducing annual consumable spend by approximately onethird while maintaining consistent 8” product sizing.

Iron Ore Processing Plant – Capacity Upgrade

Desafío: Need to increase plant capacity by >25%. Existing footprint was constrained; new equipment had to interface seamlessly with existing conveyors while offering higher reliability metrics.
Solución: A highcapacity RoHS Compliant Gyratory Crusher was selected based on its superior availability (>94%) metrics from field data in similar applications.
Resultados: The crusher met all throughput targets within the existing footprint constraints. Plantwide availability improved due to reduced primary crushing section downtime, contributing directly to achieving annual production goals.

7 . CONSIDERACIONES COMERCIALES

Equipment pricing tiers are typically structured around throughput capacity , potencia de accionamiento ,and duty rating( p.ej., Servicio estándar , Servicio pesado , Servicio extra pesado ) . Base capital investment reflects these core engineering parameters .

Optional features that provide operational value include:
Advanced predictive analytics software licenses .
Extended range lubrication conditioning units .
Specialized liner alloy packages( e.g.,for specific abrasion /impact conditions ) .
Spare part starter kits tailored to your planned maintenance schedule .

Service packages are available separately to support total cost management:
Preventive Maintenance Inspections : Scheduled audits performed by factorytrained technicians .
Onsite Repair & Overhaul Support : For major component replacement .
Remote Monitoring Support : Data analysis by application engineers .

Financing options for these capitalintensive solutions can include traditional equipment loans ,operating leases that may keep th e asset offbalancesheet ,or performancelinked agreements where repayments are partially tied to achieved throughput or availability metrics .

8 . Preguntas frecuentes

Q1 : ¿Qué hace? "RoHS Compliant" specifically mean for th e mechanical parts of a gyratory crusher ?
A1 : While th e RoHS directive primarily focuses on electrical/electronic components ,leading manufacturers extend this philosophy to th e entire supply chain . For mechanical assemblies ,this means verified documentation for restricted substances( like lead in certain bronzes or hexavalent chromium in coatings )i n any component where alternatives exist ,ensuring full traceability an d endoflife recyclability .

Q2 : How does transitioning to a modern RoHS compliant model impact our existing ancillaries like feeders an d conveyors ?
A2 : These crushers are engineered for dimensional interoperability . Key interface points—feed opening dimensions ,discharge hopper connections ,an d foundation loading data—are designed to match or be easily adapted to industrystandard layouts . Our engineering review will confirm compatibility wit h your specific setup .

Q3 : Can you quantify th e operational cost savings fro m features like th e smart chamber relief system ?
A3 : Field data shows that uncrushable material events( vagabundo de metal ,brocas )occur several times per year in typical operations . A traditional system may require a4 t o8 hour shutdown for manual clearing . Th e automated system addresses this i n under two minutes of stoppage . Preventing just one such event annually can save over $50k in lost production for a mediumsized operation .

Q4 : Are spare parts an d wear liners for these crushers more expensive du e to compliance requirements ?
A4 : Not inherently . Th e compliance mandate drives supply chain optimization rather than cost inflation . Liners an d mechanical spares are competitively priced wit h noncompliant equivalents because they are sourced fro m certified foundries an d forgemasters using controlled materials . Th e value is i n risk mitigation—ensuring part availability without regulatory obstruction .

Q5 : What is th e typical delivery lead time fro m order placement ?
A5 : Para modelos estándar ,lead times range fro m9t o14 months ,depending on current foundry capacity an d component sourcing . This timeline accounts fo r engineering ,procurement of longlead items( like main shafts ),fabricación ,an d assembly . Expedited options may be available fo r critical path projects .

Q6 : What training is provided fo r our maintenance crew ?
A6 Comprehensive training is included wit h purchase covering three areas :
1 )Operational overview fo r plant controllers .
2 )Routine inspection an d liner changeout procedures fo r millwrights .
3 )Diagnostics an d advanced troubleshooting fo r senior electricians/mechanics .
Training can be conducted at our facility during FAT( Pruebas de aceptación en fábrica )o r onsite during commissioning