1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? For plant managers and engineering contractors, the primary crushing stage is a critical bottleneck where inefficiencies cascade through the entire downstream process. Key challenges include:

Unscheduled Downtime: Premature failure of critical components like mainshafts or concaves leads to production halts costing tens of thousands per hour in lost throughput.
Excessive Maintenance Costs: Frequent, laborintensive liner changes and unpredictable wear life consume maintenance budgets and divert skilled personnel from other critical tasks.
Inconsistent Product Size: Poor feed distribution or worn crushing chambers yield an inconsistent feed for secondary circuits, reducing overall plant efficiency and final product quality.
High Energy Consumption: Inefficient crushing action and outdated drive systems result in unsustainable power draw, directly impacting your bottom line.
Limited Feed Flexibility: Inability to handle varying ore hardness or occasional tramp metal without causing significant damage.

How do you achieve higher throughput with greater reliability while controlling total cost of ownership? The answer lies in advanced gyratory crusher design focused on durability, intelligence, and efficiency.

2. PRODUCT OVERVIEW: HEAVYDUTY PRIMARY GYRATORY CRUSHER

This heavyduty primary gyratory crusher is engineered for the first stage of comminution in hightonnage mining and aggregate operations. It is designed to accept runofmine feed directly from haul trucks, delivering a consistent, coarse product to downstream conveying and processing systems.

Operational Workflow:
1. Feed Acceptance: Direct dump from haul trucks into the rugged feed hopper, guided by a onepiece spherical spider cap for optimal entry.
2. Crushing Action: The eccentrically mounted mainshaft gyrates within the concave liners, applying compressive force to reduce large rock (often +1m) to a manageable size.
3. Product Discharge: Crushed material exits through the discharge opening at the bottom of the crushing chamber, dictated by the selected crusher setting (CSS).

Application Scope & Limitations:
Scope: Ideal for highcapacity (5,000 15,000+ tph) primary crushing of abrasive hard rock (iron ore, copper ore, granite), limestone, and other minerals. Suited for fixedplant installations.
Limitations: Not designed for portable plants or lowtonnage operations (< 500 tph). Requires significant capital investment and a reinforced concrete foundation. Less effective on clayrich or highly plastic materials that may cause packing.

3. CORE FEATURES

Patented Concave Design | Technical Basis: Segmented, alloyoptimized liner system with mechanical locking | Operational Benefit: Reduces replacement downtime by up to 40% versus bolted designs; allows mixing liner profiles for optimal chamber geometry | ROI Impact: Lower labor costs per changeout and maximized liner utilization increase annual available crushing hours.

Integrated Intelligent Control System | Technical Basis: Realtime sensors monitoring pressure, temperature, power draw, and wear | Operational Benefit: Provides predictive analytics for maintenance scheduling and alerts operators to abnormal conditions like bridging or overload | ROI Impact: Prevents catastrophic failures; enables conditionbased maintenance over scheduled intervals.

Hydroset® Tramp Release & CSS Adjustment | Technical Basis: Hydraulic piston supporting the mainshaft for remote adjustment of the Closed Side Setting (CSS) | Operational Benefit: Allows quick compensation for wear or product size changes without stopping the crusher; automatically releases tramp iron | ROI Impact: Maintains product spec consistency; protects internal components from damage by uncrushables.

HighPrecision Spiral Bevel Gear & Pinion | Technical Basis: Computermodeled gear geometry manufactured to AGMA 14 quality | Operational Benefit: Ensures smooth power transmission with minimal vibration and noise; extends gear life significantly under hightorque loads | ROI Impact: Reduces risk of catastrophic drive system failure; lowers longterm spare parts inventory cost.

Centralized Automated Lubrication | Technical Basis: Programmable system delivering precise oil volumes to key bearings at set intervals | Operational Benefit: Eliminates manual lubrication errors; ensures optimal bearing temperature and longevity even in dusty environments | ROI Impact: Directly extends mean time between failures (MTBF) for critical bearings; reduces lubricant consumption.

Robust Mainshaft & Head Center Design | Technical Basis: Forged from highstrength alloy steel with precision machining on bearing journals | Operational Benefit: Provides exceptional resistance to bending fatigue and shock loads from oversized feed | ROI Impact: The core component's extended lifecycle defers major capital overhaul expenses for years.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Liner ChangeOut Time (Major) | 48 72 hours | 24 36 hours with tooling package| ~50% reduction |
| Operational Availability (Annual) | 92 94%| >96% (with Intelligent Control System)| +24 percentage points |
| Specific Energy Consumption (kWh/t) Varies by material.| Baseline = 100%| Average reduction of 58% through optimized kinematics & drive efficiency| ~7% improvement |
| Wear Life of Concaves (Abrasive Ore) MTons/Set| Varies widely by ore.| Field data shows consistent improvement of 1525% via material science & design.| ~20% increase |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable models from 3,000 to over 15,000 metric tons per hour (tph), depending on feed material and closedside setting.
Motor Power: Electric drive options from 450 kW up to 1,200 kW (600 1,600 HP). Dual pinion drives available for highest horsepower models.
Feed Opening: Gape sizes from 1,300 mm to 1,800 mm (54" to 72").
Key Material Specifications: Main frame of fabricated hightensile steel; concaves in manganese steel or optional alloy composites; mainshaft forged from NiCrMo alloy steel.
Physical Dimensions / Weight: Approximate total installed weight ranges from 400 tonnes to over 800 tonnes depending on model size. Foundation forces are provided for detailed civil engineering.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust seals and pressurized housing options available for extreme environments.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge A tierone copper miner required a primary crusher solution for a new pit expansion capable of processing highly abrasive sulfide ore at >10,000 tph while minimizing planned downtime.
Solution Installation of a superduty gyratory crusher featuring our patented concave system and intelligent controls.
Results Achieved sustained throughput of 10,500 tph. Liner life increased by an average of 22%, reducing planned changeouts from three to two per year. The control system predicted a bearing anomaly months in advance, allowing planned intervention during a conveyor shutdown.

HighProduction Granite Quarry

Challenge An aggregate producer needed consistent (8 inch) product size for their rail loadout facility but faced bottlenecks due to frequent maintenance on older equipment.
Solution Replacement with a midsize gyratory crusher equipped with Hydroset® automation.
Results CSS adjustments are now made remotely in minutes versus hours of manual work. Product consistency improved such that secondary cone crusher throughput increased by an estimated 9%. Annual maintenance hours decreased by 30%.

7. COMMERCIAL CONSIDERATIONS

Our gyratory crushers are offered under a transparent commercial framework designed for longterm partnership:

Equipment Pricing Tiers: Pricing is modelspecific based on size/capacity. Standard packages include crusher assembly motor drive auxiliary lubrication unit basic controls foundation drawings
Optional Features & Upgrades: Intelligent Control System premium wear material packages automated mantle positioning tool automated lubrication system special environmental sealing kits
Service Packages Available
Basic Warranty covers defects in materials/workmanship
Extended Service Agreement includes scheduled inspections parts discounts technical support
Full Performance Contract guaranteed availability wear part consumption service crew support
Financing Options We work with leading industrial finance providers to offer competitive leasing longterm rental or purchase plans tailored to your capital expenditure cycles

8.FAQ

Q What infrastructure is required prior installation?
A A reinforced concrete crusher foundation designed per our supplied load drawings is mandatory Access for heavy lift cranes during installation/maintenance must be considered Electrical substation capacity must match motor requirements

Q How does this integrate with our existing PLC/SCADA system?
A The crushers intelligent control system communicates via standard industrial protocols OPC UA Modbus TCP/IP providing key data points health status alarms It can function as standalone unit interface seamlessly

Q What is typical lead time delivery?
A Lead times vary by model complexity current manufacturing load Standard models typically have lead time months Custom configurations may require additional time Detailed schedule provided upon project initiation

Q Are training operator manuals provided?
A Yes comprehensive training program conducted at your site covers safe operation routine maintenance basic troubleshooting Detailed digital paper manuals parts books are supplied standard

Q Can you supply compatible downstream equipment conveyors bins?
A While we specialize primary crushing equipment we can provide interface specifications coordinate with preferred partners ensure complete circuit compatibility through project engineering phase