1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Los crecientes costos operativos y el tiempo de inactividad impredecible están erosionando la rentabilidad de su circuito de trituración primario?? Para gerentes de planta y contratistas de ingeniería, the primary crushing stage is a critical bottleneck where failures have exponential consequences. Common challenges with suboptimal gyratory crushers include:
Tiempo de inactividad excesivo no planificado: Mechanical failures or lengthy maintenance procedures can halt upstream mining and downstream processing, costando decenas de miles por hora en producción perdida.
Altos costos operativos: Premature wear part replacement, Alto consumo de energía por tonelada procesada., and frequent retightening of critical assemblies drive up your costperton metric.
Tamaño del producto inconsistente: Fluctuations in discharge settings lead to poor feed for secondary crushers and milling circuits, reducing overall plant efficiency and recovery rates.
Mantenimiento intensivo en mano de obra: Complejo, timeconsuming procedures for mantle changes or spider assembly servicing require specialized crews and extend maintenance windows.

¿Está su operación equipada para manejar las crecientes demandas de dureza del mineral y rendimiento mientras controla los costos?? The foundation of an efficient comminution circuit lies in a reliable, highcapacity primary crusher.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO: HEAVYDUTY GYRATORY CRUSHER

This heavyduty gyratory crusher is engineered for continuous, hightonnage primary crushing of runofmine ore and blasted rock. It operates on the fundamental principle of a gyrating mantle within a concave crushing chamber, delivering consistent compressive breaking force.

Flujo de trabajo operativo:
1. Consumo de alimento: Large feed material is directed into the top of the crusher via dump trucks or a shovel, entering the gap between the mantle and concaves.
2. Trituración compresiva: The eccentrically driven main shaft causes the mantle to gyrate, applying progressive compressive force to reduce material size.
3. Descargar: Crushed material falls by gravity through the narrowing chamber until it reaches the desired size and exits through the bottom discharge opening (OSS).
4. Operación continua: The design allows for continuous feeding and crushing, making it ideal for highvolume fixedplant applications.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal for largescale mining (cobre, mineral de hierro, oro), major quarry operations, and highcapacity aggregate production requiring throughput from 2,000 a más 10,000 tph. Excels with hard, materiales abrasivos.
Limitaciones: No apto para operaciones de bajo tonelaje. (<1000 tph) debido al alto costo de capital. Requires a stable concrete foundation and significant vertical space for installation. Not designed for recycling or asphalt materials.

3. CARACTERÍSTICAS PRINCIPALES

Patented QS Spider Design | Base técnica: Monolithic top shell casting with integrated rim liners | Beneficio operativo: Eliminates traditional spider bushing wear points and reduces risk of dust ingress to the eccentric bushing | Impacto del retorno de la inversión: Los datos de campo muestran una 40% reduction in spiderrelated maintenance time and associated costs.

Sello Laberíntico & Piston Ring System | Base técnica: Multistage sealing protecting critical eccentric components | Beneficio operativo: Prevents contamination from dust and water ingress while allowing lubrication system to function optimally | Impacto del retorno de la inversión: Extends major bearing service life by up to 30%, deferring sixfigure rebuild costs.

Regulación de configuración automatizada (ASR) | Base técnica: Hydromechanical adjustment system with digital control interface | Beneficio operativo: Allows operators to adjust crusher discharge setting under load in minutes versus hours | Impacto del retorno de la inversión: Minimiza el tiempo sin trituración; Las pruebas de la industria demuestran una 15% increase in annual available operating hours.

Cóncavo & Mantle Alloy Optimization | Base técnica: Metallurgical analysis leading to proprietary manganese steel alloys with microalloying elements | Beneficio operativo: Provides optimal balance of hardness and toughness for specific ore abrasiveness/impact | Impacto del retorno de la inversión: Delivers up to 20% longer service life per set compared to standard OEM parts, bajando el costo.

Integrated Smart Sensor Platform | Base técnica: Realtime monitoring of pressure, temperatura, posición, and vibration at key bearing points | Beneficio operativo: Enables predictive maintenance scheduling by identifying trends before failure occurs | Impacto del retorno de la inversión: Reduces unplanned stoppages by an estimated 60%, protecting downstream revenue flow.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Punto de referencia estándar de la industria | Nuestra solución de trituradora giratoria | Ventaja documentada |
| : | : | : | : |
| Disponibilidad (tiempo de actividad) | 92 94% disponibilidad anual >95% disponibilidad anual >3% mejora |
| Consumo de energía (kWh/tonelada) Varía según el material.; línea de base = 100% Arriba a 12% reduction in specific energy Improved motor load efficiency |
| Mantle Change Out Time Average 2436 hours Average <20 hours ~30% faster turnaround |
| Desgaste parte de la vida (Convexes) Línea de base = 100% lifecycle Up to +20% extended life Lower consumable cost per ton crushed |
| Throughput Capacity Rated design capacity Consistently achieves +57% above rated capacity Higher peak tonnage capability |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Modelos configurables desde 2,000 TPH por encima 12,000 TPH based on feed size and material characteristics.
Potencia del motor: Heavyduty synchronous motors from 450 kW hasta 1,200 kilovatios (600 1,600 caballos de fuerza), tailored to duty requirements.
Apertura de alimentación: Tamaños de apertura desde 1,370 milímetros (54") arriba a 1,830 milímetros (72").
Marco principal & Componentes: Fabricado con placa de acero de alta resistencia; mainshaft forged from highstrength alloy steel; concaves/mantles in premiumgrade manganese steel alloys.
Dimensiones físicas (Modelo grande típico): Total height ~67 meters; installed weight approximately 350 550 toneladas métricas (excluyendo la tolva de alimentación).
Rango de operación ambiental: Diseñado para temperaturas ambiente de 40°C a +50°C; dustproofed enclosures standard; paquetes opcionales árticos o tropicales disponibles.

6. ESCENARIOS DE APLICACIÓN

Proyecto de Ampliación de Mina de Cobre

Desafío: Se necesitaba una importante operación de cobre para aumentar el rendimiento de la planta en 25% but was constrained by an aging primary crusher causing weekly unplanned downtime events.
Solución: Installation of a new highcapacity gyratory crusher with integrated smart sensors and automated setting controls.
Resultados: Achieved sustained throughput at +28% above old capacity with annual availability reaching 96%. Predictive alerts reduced mechanical downtime by over USD $1.2M in lost production value in the first year.

Cantera de agregado de granito

Desafío: High silica content granite was causing accelerated concave wear every six weeks on existing equipment, leading to frequent costly shutdowns and inconsistent product gradation.
Solución: Implementation of a robust gyratory crusher paired with applicationspecific concave alloy liners.
Resultados:Liner service life extended to nine weeks consistently while maintaining tighter product size control (+/5milímetros). This change yielded a direct reduction in liner inventory costs by onethird annually.

7. CONSIDERACIONES COMERCIALES

Our wholesale distribution model provides direct access without intermediary markups.

Niveles de precios: Pricing is structured based on size/capacity (p.ej., MKII series vs MKIII series), starting at entrylevel capital investment scaling appropriately for larger configurations.
Características opcionales & Paquetes: Key options include advanced lubrication filtration systems fully automated wear part monitoring packages custom feed plate designs for sticky material conditions extended warranty plans covering major structural components
Paquetes de servicios: Choose from Bronze Silver Gold tiers covering scheduled inspections parts supply predictive analytics support emergency field service response times
Opciones de financiación: We facilitate partnerships with industrial equipment financiers offering competitive leasetoown structures operating expensebased financing or traditional term loans tailored project financing can be arranged

8. Preguntas frecuentes

Q1 Are your gyratory crushers compatible with existing plant infrastructure like feeders conveyors bins?
A1 Yes dimensional drawings power requirements foundation loads are provided early Standard discharge hoppers can be adapted Interface points are designed according global standards ensuring integration feasibility

Q2 What is typical installation commissioning timeline?
A2 For greenfield projects total timeline depends on foundation readiness Typically erection takes weeks followed by days mechanical commissioning weeks supervised performance testing Brownfield replacements can be expedited

Q3 How does this equipment impact my overall plant energy consumption?
A3 The optimized kinematics higher efficiency motors result lower specific energy use kWh per ton crushed This reduces operational expenditure improves sustainability metrics

Q4 What commercial terms are standard?
A4 Standard terms involve progress payments tied manufacturing milestones FOB shipping point Incoterms Longterm partners may qualify net payment terms after established credit history

Q5 What training is provided operational staff?
A5 Comprehensive training covers safe operation routine maintenance troubleshooting procedures Training conducted onsite during commissioning includes detailed manuals digital resources

Q6 Can you supply wear parts compatible other OEM crushers?
A6 Yes our foundry produces premium compatible liners spiders other wear components several legacy models often superior metallurgy competitive pricing

Q7 How do you handle urgent breakdown situations?
A7 Our Goldtier service package guarantees priority parts dispatch dedicated technical support hotline If required field service engineers can be mobilized within agreed response windows detailed SLA