1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? Plant managers and engineering contractors consistently face critical challenges in gyratory crusher operations that directly impact the bottom line.

Excessive Downtime for Maintenance: Scheduled mantle and concave changes can halt your entire primary feed line for days, costing thousands per hour in lost production.
Unplanned Stoppages from Feed Issues: Bridging, packing, or uneven feed distribution leads to costly, reactive interventions and potential damage to the crusher’s core components.
Rising Energy Consumption: Inefficient crushing chambers and outdated drive systems consume disproportionate power without delivering optimal reduction, inflating operational expenses.
Inconsistent Product Size & Capacity: Wear over time alters the crushing cavity, leading to offspec product that stresses downstream processes and limits overall plant throughput.

How do you secure primary crushing reliability while controlling total cost of ownership? The solution requires equipment engineered not just for peak performance, but for sustained, efficient operation with minimal operational disruption.

2. PRODUCT OVERVIEW

The modern highcapacity gyratory crusher is a stationary primary crushing solution designed for the most demanding mining and aggregate applications. It processes runofmine ore or large quarry rock into a consistent feed for secondary circuits.

Operational Workflow:
1. Feed Intake: Large dump trucks or loaders deposit material directly into the crusher’s robust feed hopper.
2. Crushing Action: The central gyrating mantle eccentrically compresses material against the stationary concave liners, applying progressive compression to fracture the rock.
3. Discharge: Crushed product exits through the adjustable discharge opening at the bottom of the chamber, with size determined by the closedside setting (CSS).

Application Scope: Ideal for hightonnage (1,500+ tph) hard rock mining (copper, iron ore, gold), largescale aggregate production, and heavyduty industrial mineral processing.

Limitations: Not suitable for lowtonnage operations (<500 tph), highly abrasive but lowstrength materials where other crusher types may be more economical, or sites with extreme space constraints where a mobile primary might be necessary.

3. CORE FEATURES

Intelligent Chamber Design | Technical Basis: Optimized nip angle and crushing cavity profile | Operational Benefit: Delivers consistent reduction ratio with lower risk of bridging and reduced recirculating load | ROI Impact: Maximizes throughput yield per energy unit, reducing costperton

Patented Liner Retention System | Technical Basis: Mechanically locked concave segments with backing material | Operational Benefit: Eliminates backing material failures and allows for faster, safer liner changes | ROI Impact: Reduces planned maintenance downtime by up to 30%, increasing annual available operating hours

Integrated Automatic Setting Regulation | Technical Basis: Hydraulic adjustment and monitoring of the main shaft position | Operational Benefit: Allows operators to adjust CSS under load or remotely to maintain product size without stopping | ROI Impact: Maintains downstream process stability and final product specification, minimizing value loss

HighTorque Direct Drive System | Technical Basis: Lowspeed synchronous motor coupled directly to the eccentric | Operational Benefit: Eliminates gear train inefficiencies, provides smooth startup under load, and reduces mechanical complexity | ROI Impact: Field data shows 812% improvement in energy efficiency compared to traditional geared drives

Advanced Condition Monitoring Ports | Technical Basis: Integrated sensors for lubrication pressure/temperature, shaft position, and wear monitoring | Operational Benefit: Enables predictive maintenance planning by providing realtime health data on critical systems | ROI Impact: Prevents catastrophic failures, extends component lifecycles, and optimizes maintenance scheduling

Spiderless Design Option (for smaller models) | Technical Basis: Eliminates the traditional spider bridge at the top of the crusher | Operational Benefit: Provides safer access for maintenance personnel and simplifies feed arrangement installation | ROI Impact: Reduces safety incident risk and shortens inspection times

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Liner Changeout Time| 4872 hours (full mantle/concave) | 3648 hours with patented system| 2533% faster, increasing availability |
| Energy Efficiency (kWh/ton)| Varies by material; baseline established per project| Optimized chamber & direct drive reduce consumption| 812% improvement in specific energy use |
| Mean Time Between Failure (MTBF)| Dependent on maintenance rigor; typical major component intervals apply| Enhanced bearing design & filtration extend service life| Major component life extended by 1520% |
| Availability (Annual)| 9294% for wellmaintained units| Design focus on reliability & predictive monitoring targets >96%| Targets a 24 percentage point increase, yielding significant extra tonnage |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 1,500 to over 12,000 metric tons per hour (tph), dependent on model selection, feed material, and closedside setting.
Motor Power Requirements: Typically from 450 kW up to 1 MW+; designed for highvoltage (6.6kV 11kV) industrial power supply with softstart capability.
Material Specifications: Main frame of fabricated highstrength steel; concaves and mantles available in premium manganese steel alloys or composite materials for specific abrasion/impact conditions.
Physical Dimensions & Weight: Varies significantly by model; largest units can exceed 10 meters in height and weigh over 500 tons. Foundation loading specifications are provided per project.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust sealing systems are standard; optional kits are available for extreme environments.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: An existing mine expansion required a new primary crusher capable of handling 6,000 tph of abrasive copper porphyry ore while fitting within constrained space in an expanded pit perimeter.
Solution: Installation of a compact topservice gyratory crusher with a spiderless design.
Results: Achieved design throughput within three months of commissioning. The simplified access reduced planned service stops by an average of 18 hours per event compared to the site's older units.

HighProduction Granite Aggregate Quarry

Challenge: A coastal quarry needed to increase finished base material production but faced prohibitive energy costs and excessive wear on its existing primary jaw crusher when processing hard granite.
Solution: Replacement with an energyfocused gyratory crusher featuring an intelligent chamber profile and direct drive system.
Results: Plant throughput increased by 22%. Specific energy consumption (kWh/ton) decreased by 9%, resulting in a calculated payback period of under three years based on energy savings alone.

7. COMMERCIAL CONSIDERATIONS

Gyratory crushers represent a significant capital investment tailored precisely to project requirements.

Pricing Tiers: Capital cost is primarily determined by size/capacity (e.g., 4265”, 5475”, 6089” models), drive system selection (direct vs. geared), and level of automation integration.
Optional Features & Packages: Common options include advanced lubrication filtration systems automated wear part measurement devices remote control interfaces specific liner material grades
Service Packages: Comprehensive Life Cycle Service contracts are available covering scheduled maintenance parts supply (with guaranteed inventory holding) predictive monitoring support field service engineering
Financing Options: We work with major industrial financing partners to offer flexible solutions including capital lease operating lease or projectbased financing structures aligned with your mine plan or project cash flow

8. FAQ

Q1: Is this gyratory crusher compatible with our existing plant control system?
A1 Most modern units come equipped with industrystandard communication protocols Modbus TCP/IP OPC UA allowing integration into most supervisory control SCADA systems Interface documentation is provided for your engineering team

Q2 What is the expected operational impact during installation?
A2 Installation requires significant planning foundation work mechanical erection electrical connection Typical greenfield installation timelines range from four six months Brownfield replacements require a coordinated plant shutdown usually four eight weeks depending on complexity

Q3 How does this equipment improve our overall costperton metric?
A3 The improvement comes from multiple factors higher availability reduces fixed cost allocation per ton lower energy consumption reduces variable costs extended liner life decreases consumable costs Combined these deliver a measurable reduction in total operating cost over the equipment lifecycle

Q4 What commercial terms are standard?
A4 Equipment sales typically follow FCA Incoterms at our manufacturing facility Longerterm service agreements have defined terms scope pricing schedules based on annual operating hours Support is quoted separately based on required response times parts coverage levels

Q5 What training is provided for our operations maintenance teams?
A5 Comprehensive training is included covering normal operation emergency procedures routine checks major component replacement This includes both classroom instruction handson training during commissioning Documentation includes detailed operation maintenance manuals parts lists