1. PAINPOINT DRIVEN OPENING

Managing an iron ore crushing circuit presents distinct, costly challenges. Are you experiencing persistent bottlenecks that limit your plant’s rated throughput? Are unscheduled maintenance stops and premature wear part failures eroding your operating budget and creating unpredictable downtime? Is inconsistent product sizing leading to inefficiencies in downstream grinding and processing, ultimately affecting pellet or sinter quality? Furthermore, does the total cost of ownership for your primary crushing stage—factoring in energy consumption, liner replacements, and labor—exceed initial projections? These operational hurdles directly impact profitability. The central question for plant managers is this: how can you achieve reliable, hightonnage reduction of abrasive iron ore while controlling operational costs and maximizing plant availability?

2. PRODUCT OVERVIEW

This product is a Primary Gyratory Crusher engineered specifically for highcapacity iron ore processing. It is designed as the first critical stage in a mineral processing plant, receiving runofmine (ROM) feed directly from the pit.

Operational Workflow:
1. Feed Intake: ROM iron ore (up to 1.5m lump size) is dumped into the crusher’s deep, nonchoking receiving hopper.
2. Crushing Action: A centrally mounted mantle gyrates within a concave bowl, applying compressive force to break the ore against itself.
3. Discharge: Crushed material exits through the bottom setting (CSS), with product size typically ranging from 150mm to 250mm for feed to secondary crushing or SAG mill circuits.

Application Scope & Limitations:
Scope: Ideal for largescale mining operations with high daily tonnage requirements (>10,000 MTD). Suited for processing hard, abrasive hematite and magnetite ores.
Limitations: Not designed for final product sizing or for processing materials with high clay or moisture content without adequate prescreening/scalping. Requires a stable concrete foundation and significant headroom for installation and maintenance.

3. CORE FEATURES

Patented Concave Design | Technical Basis: Segmented, reversible alloy steel segments | Operational Benefit: Extends service life by up to 30% by allowing rotation and use of multiple wear surfaces before replacement | ROI Impact: Reduces liner inventory costs and downtime for concave changes

Integrated Automatic Setting Regulation | Technical Basis: Hydraulic adjustment system with position sensors | Operational Benefit: Allows operators to adjust the crusher discharge setting in minutes without stopping the process | ROI Impact: Maintains optimal product size for downstream efficiency, increasing overall circuit throughput by an estimated 25%

Lube System with Condition Monitoring | Technical Basis: Dualcircuit filtration and temperature/pressure sensors feeding to plant DCS | Operational Benefit: Provides continuous protection of critical bearings; alerts personnel to potential issues before failure occurs | ROI Impact: Prevents catastrophic bearing damage, a failure that can result in over 200 hours of lost production

SpiderMounted Dump Hopper & Seal | Technical Basis: Reinforced design with multistage dust seal system | Operational Benefit: Effectively contains dust at the feed point and prevents contaminant ingress into the main bearing assembly | ROI Impact: Reduces environmental emissions compliance costs and extends bearing life in dusty conditions

HeavyDuty Main Shaft Design | Technical Basis: Forged alloy steel shaft with optimized fatigue resistance profile | Operational Benefit: Provides exceptional strength to handle tramp steel and uncrushable material events without shaft deflection or failure | ROI Impact: Eliminates unplanned outages related to shaft failure, a primary cause of extended downtime in primary crushing

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Competitor Averages) | This Primary Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Scheduled Runtime) | 9294% | 96%+ documented field average over 24 months | ~34% improvement |
| Liner Life (Million Tons/Set) Hematite Ore| 4.5 5.5 Mtons | 6.0 7.0 Mtons verified at multiple sites| ~1520% improvement |
| Specific Energy Consumption (kWh/ton) | 0.18 0.22 kWh/t | 0.15 0.17 kWh/t based on installed motor vs. throughput data| ~18% improvement |
| Tramp Iron PassThrough Recovery Time| Manual clearing; hours of downtime| Hydraulic clearing system; 80% reduction in event duration |

5. TECHNICAL SPECIFICATIONS

Model Designation: PGC60110
Feed Opening: 1,520 mm (60 inches)
Nominal Capacity Range: 3,500 7,500 mtph (dependent on ore characteristics and discharge setting)
Installed Power: 600 kW (800 HP) electric drive motor
Main Shaft: Forged ES355 alloy steel
Concave & Mantle Material: ASTM A128 Manganese Steel with proprietary heat treatment
Total Weight (Crusher Only): ~275 metric tons
Top Shell Diameter: ~4.8 meters
Operating Temperature Range: 30°C to +45°C (with appropriate lube oil specifications)
Dust Control: Integral connection points for plant dust extraction system.

6. APPLICATION SCENARIOS

LargeScale Open Pit Mine – Australia Challenge:

A major hematite operation faced declining feed grades, requiring higher throughput volumes through their primary crushing station to maintain annual production targets. Their existing crusher was unable to achieve higher tonnage without excessive wear and energy costs.

Solution:

Implementation of one PGC60110 Primary Gyratory Crusher with the integrated automatic setting system.

Results:

Within six months of commissioning:
Sustained throughput increased by 18%, meeting upgraded plant demands.
Energy cost per ton crushed decreased by 16%.
Annual planned maintenance hours were reduced by 120 hours due to extended liner intervals.

Magnetite Concentrator – North America Challenge:

The client’s new greenfield project required a primary crusher capable of handling extremely hard magnetite ore while guaranteeing >95% availability as the single point of failure for the entire coarse ore circuit.

Solution:

Installation of two PGC60110 crushers configured with full condition monitoring on lube systems and main bearings.

Results:

Over the first two years of operation:
Achieved an average operational availability of 96.7%.
Successfully passed multiple tramp metal events without damage via the hydraulic release system.
Condition monitoring provided actionable data that allowed scheduling of a bearing inspection during a planned plant shutdown, avoiding a predicted inservice failure.

7 COMMERCIAL CONSIDERATIONS

Our commercial model is structured around providing predictable total cost outcomes.

Equipment Pricing Tiers: Pricing is based on configuration.
Base Configuration: Core crusher assembly with standard lubrication unit.
Advanced Configuration: Includes automatic setting regulation (ASR), advanced condition monitoring sensors, and upgraded dust sealing.
Turnkey SkidMounted Unit: Crusher preassembled on a structural skid base with walkways, ladders, and integrated lubrication system for faster installation.

Optional Features & Upgrades: Wear monitoring systems via concave wear sensors; premium ceramic composite liners for specific abrasion zones; custom discharge conveyor flanges; extended warranty packages on major castings.

Service Packages:
Planned Maintenance Agreement: Scheduled inspections, oil analysis programs, and technical support.
Liner Service Contract: Guaranteed liner life performance with fixedcostperton replacement parts.
FullService Contract: Covers all parts (wear & mechanical), labor, and field service engineering for a fixed annual fee.

Financing Options: We offer several capital solutions including traditional equipment financing/leasing through our partners or performancebased contracting models where payments can be partially linked to achieved availability or throughput guarantees.

8 FAQ

1.Q What is the lead time from order placement to delivery?
A For standard models like the PGC60110 lead times are typically between 912 months due to extensive forging and machining requirements for major components like the main shaft and top shell castings

2.Q How does this crusher integrate with our existing PLC/SCADA control system?
A The unit comes standard with an AllenBradley ControlLogix PLC local panel All critical operational data pressure temperature motor status ASR position are communicated via industrystandard Modbus TCP/IP or Ethernet/IP protocols allowing straightforward integration into your wider plant control network

3.Q What are your recommendations regarding feed size distribution?
A For optimal performance we recommend ROM feed where no more than XNUMX% exceeds XNUMX times the nominal feed opening size Consistent feeding using a vibrating grizzly feeder or apron feeder is critical Our engineering team can review your specific mine plan geology data

4.Q Do you provide installation supervision?
A Yes we offer optional expert field service supervision during installation commissioning This service ensures correct mechanical alignment electrical connection verification lubrication system flushing procedure adherence which directly impacts longterm reliability

5.Q What are typical spare parts inventory recommendations?
A We provide sitespecific recommendations based on your operating schedule However we maintain regional stockholding centers globally offering XNUMX/XNUMX emergency parts dispatch Critical spares like main shaft step washers eccentric bushings should be held onsite per our recommended list

6.Q Can you guarantee performance metrics like capacity or liner life?
A Formal performance guarantees are provided as part of our commercial proposal following detailed review analysis of your representative ore samples geotechnical data These guarantees form part binding contract subject defined test protocols postcommissioning