1. PAINPOINT DRIVEN OPENING

Are your gold processing operations constrained by unreliable or inefficient primary crushing? The initial size reduction stage sets the tone for your entire recovery circuit. Common challenges with suboptimal gold ore crushing equipment include:
Excessive Downtime: Frequent liner changes, unplanned maintenance, and component failures halt your milling circuit, costing thousands per hour in lost production.
Low Throughput of HighGrade Ore: Inefficient crushing creates bottlenecks, preventing your plant from processing more valuable material and maximizing revenue during peak price cycles.
Poor Particle Size Distribution: Inconsistent product size increases load on grinding mills, elevating specific energy consumption (kWh/t) and wearing mill liners prematurely.
High Operational Costs: Skyrocketing energy consumption, coupled with frequent replacement of wear parts under abrasive conditions, erodes profit margins.
Difficulty with Variable Ore Hardness: A single blast can produce a mix of soft oxide and hard sulfide material, challenging crushers not built for such fluctuation.

Is your current setup causing unpredictable downtime and limiting your plant’s potential? What if your primary crusher could deliver consistent fragmentation, reduce energy costs per ton, and improve overall circuit availability?

2. PRODUCT OVERVIEW

This product line focuses on robust, stationary primary jaw crushers engineered specifically for the demanding first stage of gold ore crushing. Designed to accept runofmine (ROM) feed directly from haul trucks, these machines provide the reliable, highcapacity reduction required for optimal downstream cyanidation or gravity recovery.

Operational Workflow:
1. ROM ore (up to 1200mm) is dumped directly into the crusher’s vibrating grizzly feeder (VGF).
2. The VGF removes fines and directs oversize material into the deep crushing chamber of the jaw crusher.
3. A highinertia flywheel and optimized kinematics ensure a powerful compressive force to break even the most stubborn quartz veins or sulfide bands.
4. Crushed product is discharged at a consistent, adjustable CSS (Closed Side Setting), typically between 150200mm, ready for secondary crushing or conveyor transport.

Application Scope: Ideal for hard rock gold ores (lode deposits), including quartzite, greenstone belts, and sulfidic ores. Suitable for both greenfield installations and retrofit projects aiming to debottleneck existing circuits.

Limitations: Not designed for wet, sticky placer or alluvial material without significant feed system modification. Primary jaw crushers are a fixed installation; mobile solutions are configured differently.

3. CORE FEATURES

HeavyDuty Frame & Kinematics | Technical Basis: Finite Element Analysis (FEA) optimized stress distribution | Operational Benefit: Unmatched structural integrity under shock loads from large feed blocks; extends bearing and component life by over 40% in field data | ROI Impact: Reduces risk of catastrophic frame failure and associated weeks of downtime, protecting capital investment.

AbrasionResistant Jaw Dies | Technical Basis: Manganese steel alloy with patented Quenching & Tempering process | Operational Benefit: Achieves up to 30% longer service life in highly abrasive siliceous ores compared to standard alloys | ROI Impact: Lowers costperton for wear parts and reduces frequency of hazardous liner changeout procedures.

Automated Wedge Adjustment System | Technical Basis: Hydraulic shim adjustment with remote control capability | Operational Benefit: Allows operators to adjust CSS in minutes without manual shim handling, facilitating quick optimization for changing ore characteristics | ROI Impact: Increases plant availability by reducing adjustment downtime from hours to minutes; improves yield by maintaining target product size.

Integrated Dust Suppression Manifold | Technical Basis: Pressurized water spray bars integrated into feed chute & discharge point | Operational Benefit: Effectively controls silica dust at transfer points, ensuring compliance with health regulations (MSHA/OSHA) | ROI Impact: Mitigates risk of work stoppages due to air quality violations and reduces longterm liability from worker health claims.

HighCapacity Vibrating Grizzly Feeder (VGF) | Technical Basis: Robust deck design with adjustable grizzly bar spacing | Operational Benefit: Scalps fines efficiently to bypass the crusher, reducing chamber wear and increasing effective throughput of oversize material by up to 15% | ROI Impact: Directly lowers energy consumption per ton crushed and maximizes crusher utilization for its intended duty.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for Primary Jaw Crushers | Our Gold Ore Crushing Equipment Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime)| 9294% | 9698% | +4% improvement |
| Wear Life (Abrasive Ore)| ~450,000 tons per set of jaw dies| ~600,000 tons per set of jaw dies| +33% longer life |
| Energy Efficiency| Standard motor sizing with fixed RPM| TEFC highefficiency motors with optional VFD control| Up to 8% lower kWh/ton |
| CSS Adjustment Time| Manual shim adjustment (24 hours)| Hydraulic wedge adjustment (<30 minutes)| Up to 85% faster |
| Mean Time Between Failure (MTBF)| Varies widely; ~1,500 hours for critical components| Documented MTBF >2,200 hours on major assemblies| >30% improvement |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: 500 2,500 tonnes per hour (tph), depending on feed size and ore hardness.
Feed Opening: From 900mm x 600mm up to 1500mm x 1200mm.
Power Requirements: Main crusher motor from 75 kW to 250 kW. Total installed power including VGF typically ranges from 110 kW to 350 kW.
Material Specifications: Main frame fabricated from highgrade steel plate (min. yield strength 355 MPa). Jaw dies manufactured from premium Mn18Cr2 alloy steel.
Physical Dimensions: Footprint tailored to model; approximate L x W x H range: 8m x 4m x 5m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Bearings are protected against dust ingress via labyrinth seals and optional air purge systems.

6. APPLICATION SCENARIOS

West African Hard Rock Mine Retrofit

Challenge: An existing operation using an older primary crusher faced throughput limitations below design capacity due to frequent blockages and slow wear part changes on hard sulfide ore.
Solution: Implementation of a new heavyduty jaw crusher featuring hydraulic CSS adjustment and our proprietary abrasionresistant jaw die alloy.
Results: Throughput increased by 22%, achieving nameplate capacity. Liner changeout frequency decreased from every 6 weeks to every 8 weeks despite higher tonnage processed.

North American MidTier Gold Producer

Challenge: High variability in ore hardness within a single pit led to inconsistent product size distribution from the primary stage overloading the SAG mill circuit.
Solution Installation of a primary jaw crusher equipped with an advanced VGF system paired with variable frequency drive control on the main motor allows realtime optimization based on load sensing
Results Achieved a more consistent P80 transfer size reducing SAG mill specific energy consumption by an average of 9%. Overall plant stability improved significantly

Junior Miner Greenfield Project

Challenge Required reliable startup equipment that could handle initial high grade zones while being scalable without requiring total replacement as production ramped up
Solution Selection was based on modular design allowing future upgrades such as larger motors or different liner profiles without altering foundation plans
Results Project commissioning was completed within schedule The equipment provided operational reliability exceeding 97% in first year allowing focus on metallurgical recovery optimization

Commercial Considerations

Pricing is structured according to capacity rating robustness level required

Base Equipment Tier Includes core crusher VGF basic walkways guards lubrication system motors starters

Optional Features Premium wear protection packages advanced automation PLC integration remote monitoring sensors extended dust suppression systems custom discharge conveyor modules

Service Packages Available options range from basic commissioning supervision through comprehensive multi year planned maintenance agreements which include scheduled inspections guaranteed parts supply priority technical support These agreements have demonstrated ability reduce total lifecycle costs by up 18%

Financing Options We work with established partners offer flexible commercial terms including capital lease operating lease lease purchase structures tailored cash flow requirements typical mining project cycles

FAQ

What if my gold ore contains significant clay or moisture content?
While designed primarily hard rock applications we can configure pre screening scalping options mitigate handling issues sticky material may require consultation our engineering team assess specific conditions

How does this equipment integrate existing secondary tertiary crushing grinding circuit?
Our technical team will review your current flowsheet provide detailed interface drawings ensure compatibility conveyor speeds bin capacities electrical loads Smooth integration is standard part our project scope

What is typical delivery lead time?
For standard models lead time ranges 16 weeks ex works Custom configurations may require additional engineering time We maintain strategic stock critical wear components expedite delivery when needed

Do you offer performance guarantees?
Yes we provide guaranteed minimum throughput capacity based agreed feed specifications along with maximum power consumption figures These are backed comprehensive factory testing prior shipment

What training provided our operations maintenance staff?
We include comprehensive onsite training during commissioning covering safe operation routine maintenance procedures troubleshooting guides This is supplemented detailed digital documentation video resources