1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your primary crushing circuit’s profitability? Plant managers and engineering contractors consistently face critical challenges with their primary crushing assets:
Unscheduled Downtime: Premature wear or failure of critical components can halt your entire processing line, costing tens of thousands per hour in lost production.
Excessive Maintenance Costs: Frequent liner changes, lengthy maintenance windows, and high parts consumption directly impact your bottomline operating expenditure.
Inconsistent Throughput: Inefficient crushing chambers or suboptimal feed conditions lead to fluctuating tonnage, creating bottlenecks for downstream processes.
High Energy Consumption: Older or poorly designed crushers operate with low mechanical efficiency, making power costs a significant and growing operational burden.
Rigidity to Feed Variation: Hard, abrasive ores or unexpected feed sizes can cause chokeups or accelerated wear, forcing production rate compromises.

Is your operation in need of a robust, highcapacity primary crusher engineered not just for peak performance, but for sustained reliability and lower total cost of ownership?

2. PRODUCT OVERVIEW

A Gyratory Crusher is a stationary primary crushing machine central to largescale mining and aggregate operations. It utilizes a gyrating mantle within a concave housing to compress and fracture large feed material (typically above 1 meter in size) into smaller, manageable rock for secondary processing.

Operational Workflow:
1. Feed Intake: Runofmine ore or large quarry rock is directed into the top of the crusher’s deep, rugged chamber via haul trucks or feeders.
2. Compressive Crushing: The eccentrically driven mantle gyrates within the stationary concave liners, applying compressive force to reduce particle size through repeated cycles.
3. Discharge: Crushed material gravitates downward through the narrowing chamber until it reaches the desired size and exits through the discharge opening at the bottom.

Application Scope & Limitations:
Scope: Ideal for hightonnage (1,500+ TPH) primary crushing applications in hard rock mining (copper, iron ore, gold), large aggregate quarries, and major industrial mineral processing. Excels with abrasive and highstrength materials.
Limitations: Requires significant capital investment and substantial physical footprint. Not suitable for smallscale operations, mobile plants, or handling highly plastic or claybound materials that may cause packing.

3. CORE FEATURES

Patented Concave Profile | Technical Basis: Optimized crushing chamber geometry | Operational Benefit: Delivers consistent product gradation and maximizes throughput across the liner life cycle | ROI Impact: Reduces downstream circuit variability; field data shows a 58% increase in average throughput versus conventional profiles.

Integrated Intelligent Control System | Technical Basis: Realtime condition monitoring (pressure, temperature, position) & automation interface | Operational Benefit: Your operators can optimize load distribution, predict maintenance needs, and prevent catastrophic damage | ROI Impact: Prevents unplanned stops; industry case studies correlate this system with a 1520% reduction in major component failure rates.

HeavyDuty Main Shaft & Shell Design | Technical Basis: Forged alloy steel shaft and robust spider assembly | Operational Benefit: Provides exceptional strength to withstand peak loads from uncrushable tramp material without structural damage | ROI Impact: Eliminates costly shaft replacement events; extends major assembly service life by years.

Lube System with Dual Coolers | Technical Basis: Highvolume circulation with redundant heat exchange capacity | Operational Benefit: Maintains optimal bearing temperature even in ambient conditions exceeding 45°C (113°F), ensuring viscosity stability | ROI Impact: Directly protects the highestvalue bearings; documented to extend bearing life by up to 30% in hotclimate operations.

TopService Design Philosophy | Technical Basis: All routine service points accessed from above via removable assembly | Operational Benefit: Enables safer, faster liner changes and inspection without personnel working beneath suspended loads | ROI Impact: Reduces planned maintenance downtime by up to 40% for liner replacement tasks.

HighEfficiency Drive System | Technical Basis: Direct gear drive or lowslip VSD coupling configured for your power grid | Operational Benefit: Transmits power with minimal parasitic loss; softstart capability reduces grid stress during startup | ROI Impact: Energy consumption analysis indicates 37% lower specific energy use (kWh/ton) compared to legacy directtie designs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Availability (Operating Time) | 92 94% | > 96% | +24 percentage points |
| Liner Life (Abrasive Ore) | ~6 Months | 7 8 Months| +1520% improvement |
| Specific Energy Consumption| Baseline (100%)| ~9395% of baseline| 57% reduction |
| Mean Time Between Failure (Major)| ~24 Months| >36 Months| +50% increase |
| Throughput per Installed kW| Varies by model| Optimized chamber flow increases average yield by volume |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2,000 to over 10,000 metric tons per hour (tph), dependent on model selection and feed material.
Motor Power Requirements: Typically from 450 kW up to 1,200+ kW. Engineered for compatibility with global voltages (e.g., 6.6 kV, 11 kV) and includes motor starter recommendations.
Material Specifications: Key wear components manufactured from proprietary highstrength manganese steel alloys or composite materials. Main shaft is forged from vacuumdegassed alloy steel.
Physical Dimensions & Weight: Total installed weight ranges from approximately 250 tonnes to over 500 tonnes. Comprehensive foundation loading diagrams are provided for engineering design.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C (40°F to +122°F). Sealing systems are rated for highdust environments common in mining applications.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: A tierone copper operation needed to debottleneck its primary circuit to handle harder ore from a new pit zone. Their existing crusher suffered from low availability due to bearing overheating and frequent concave cracking.
Solution: Implementation of a new heavyduty gyratory crusher featuring the dualcooler lube system and patented concave design suited for highly compressive ore.
Results: Achieved sustained throughput of over 6,500 tph with availability consistently above 96%. Specific energy consumption decreased by an average of ~6%, while liner life extended from an average of five months to seven months.

Major Granite Aggregate Producer

Challenge: A coastal quarry supplying megainfrastructure projects faced excessive maintenance time on its primary crusher due to complex liner change procedures causing unpredictable plant shutdowns.
Solution: Installation of a topservice gyratory crusher designed specifically for abrasive granite feed.
Results: Topservice access reduced planned liner change downtime by approximately onethird per event—translating to over four additional production days annually—and significantly improved worker safety during maintenance tasks.

7. COMMERCIAL CONSIDERATIONS

Our gyratory crushers are offered across several tiers based on size capacity:
Standard Duty Series: For hightonnage aggregate applications (<12k Mpa compressive strength).
Heavy Duty Series (Recommended for Mining): Engineered for continuous operation with hard/abrasive ores (>12k Mpa).
Optional features include advanced predictive analytics packages integrated into the control system custom wear protection packages based on specific ore abrasion indices remote diagnostic support capabilities

We offer comprehensive service agreements covering parts supply technical support scheduled inspections These can be structured as fixedcost annual plans providing budget certainty

Financing options including equipment leasing capital expenditure loans project financing structures are available through our network partners facilitating cash flow management

FAQ

1. Q How do I determine if this gyratory crusher is compatible with my existing plant footprint?
A We provide detailed dimensional layout drawings including all service clearances Our engineering team can conduct a site integration review using your existing plans

2 Q What is the expected impact on my overall plant throughput?
A Based on historical data our optimized chamber designs typically deliver more consistent product sizing which often increases downstream milling circuit efficiency contributing directly higher overall plant yield

3 Q What are typical lead times?
A Lead times vary based on model complexity current order book For standard heavyduty models typical manufacturing delivery ranges between months We provide firm schedules upon project commitment

4 Q How does pricing compare total cost ownership versus other options?
A While initial capital investment is significant field performance reports confirm that superior availability longer component life lower energy consumption result lower operating cost per ton crushed which defines true value over year lifespan

5 Q What level technical support provided during commissioning?
A Commissioning supervised our experienced field engineers includes operator training performance baselining final system tuning ensure design specifications met We remain available remote support thereafter