1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability undermining 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. Common challenges with outdated or underperforming gyratory crushers include:

Excessive Unplanned Downtime: Frequent mechanical failures, such as bottom shell bushing wear or mainshaft issues, lead to production halts costing tens of thousands per hour in lost throughput.
High Maintenance Costs & Labor Intensity: Traditional designs require lengthy, complex procedures for wear part inspection and replacement, demanding significant manhours and specialized tooling.
Inconsistent Product Size & Capacity: Worn or poorly adjusted crushers produce offspec feed for secondary circuits, reducing overall plant efficiency and final product yield.
Rising Energy Consumption: Inefficient crushing chambers and outdated drive systems consume excessive power per ton of processed material, directly impacting operating expenses.

Is your operation equipped to handle increasing ore hardness and throughput demands while controlling maintenance budgets? The solution lies in selecting a gyratory crusher backed by robust engineering and a verifiable manufacturer certificate.

2. PRODUCT OVERVIEW: HEAVYDUTY PRIMARY GYRATORY CRUSHER

This equipment is a highcapacity, compressivestyle primary gyratory crusher engineered for the first stage of reducing runofmine ore or quarry rock. Its core function is to accept large feed material (typically up to 1.5m in size) and reliably deliver a consistent, coarse product for conveyor transport to subsequent processing stages.

Operational Workflow:
1. Feed Acceptance: Large dump trucks or loaders deposit material directly into the crusher’s feed hopper.
2. Compressive Crushing: The central gyrating mantle eccentrically compresses material against the stationary concave liners, fracturing rock via highpressure compression.
3. Discharge: Crushed material gravitates through the increasingly narrow chamber until it reaches the desired size and exits through the discharge opening at the bottom.

Application Scope: Ideal for hightonnage (2,000+ tph) mining of hard rock metals (copper, iron ore) and largescale aggregate quarry operations. It is the preferred solution for abrasive materials and blocky feeds where high availability is nonnegotiable.

Limitations: Not suitable for lowtonnage operations (<500 tph) due to high capital cost. Requires a stable, reinforced concrete foundation and significant headroom for installation and maintenance. Less effective for processing clayey or highly plastic materials that may cause packing.

3. CORE FEATURES

Patented Spider Design | Technical Basis: Multiarm, forged steel construction with top shell bushing integration | Operational Benefit: Provides superior load distribution and alignment for the mainshaft, reducing stress concentrations | ROI Impact: Extends service intervals by up to 30%, lowering lifetime structural repair costs.

Integrated Automatic Setting Regulation (ASR) | Technical Basis: Hydraulic adjustment system with realtime position sensors | Operational Benefit: Allows operators to adjust the crusher discharge setting (CSS) under load in under one minute | ROI Impact: Minimizes downtime for product size changes by over 95% compared to manual shim adjustment.

Concave Segment Locking System | Technical Basis: Radial mechanical locking bolts accessible from top | Operational Benefit: Enables safe, faster concave liner changes without entering the crushing chamber from below | ROI Impact: Reduces liner replacement downtime by approximately 40%, increasing annual available operating hours.

HighPerformance Main Shaft Design | Technical Basis: Forged from highstrength alloy steel with precisionmachined bearing surfaces | Operational Benefit: Withstands extreme cyclical loading with minimal deflection, ensuring consistent cavity geometry | ROI Impact: Improves bearing life by an average of 15% based on field data, reducing major component replacement frequency.

StateoftheArt Lubrication System | Technical Basis: Dualcircuit, temperaturecontrolled filtration with failsafe monitoring | Operational Benefit: Ensures clean oil delivery to critical bearings under all operating conditions; continuous contamination removal extends oil life | ROI Impact: Prevents an estimated 70% of bearingrelated failures, avoiding associated unplanned stoppages.

Robust Bottom Shell Bushing Assembly | Technical Basis: Precisionfitted bronze bushings with optimized lubrication grooves | Operational Benefit: Maintains accurate eccentric throw under peak loads for consistent throughput and product gradation | ROI Impact: Directly contributes to achieving rated capacity targets over longer campaigns, maximizing revenue potential.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Mechanical Availability (Annual) | 92 94%| 96 97%| +3% improvement |
| Liner Change Downtime (Major Set) | 36 48 hours| 24 30 hours| ~35% faster |
| Energy Consumption (kWh/tonne) Varies by material.| Baseline = 100%| 92 95%| 58% more efficient |
| Mean Time Between Failure (MTBF) Critical Assemblies| ~4,500 hours| >6,000 hours| +33% reliability |

Note: Advantages are based on internal field performance audits comparing previous generation models against current design under comparable conditions.

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2,000 to over 10,000 metric tonnes per hour (tph), dependent on model selection and feed material.
Motor Power: Standard drives from 450 kW up to 1,200 kW.
Feed Opening: Gape sizes from 1,050 mm (42") to 1,500 mm (60").
Discharge Setting Adjustment Range: Typically from 130mm to 280mm CSS.
Key Material Specifications:
Main Frame & Top Shell: Hightensile cast steel.
Mantle & Concave Liners:Manganese steel alloys (Standard); Optional chromewhite iron or composite alloys for highly abrasive feeds.
Main Shaft:Carbonchromemolybdenum forged steel.
Approximate Installed Weight: Ranges from ~250 tonnes to >600 tonnes depending on size.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust sealing systems are rated for operational altitudes up to 3,000 meters above sea level.

6. APPLICATION SCENARIOS

Copper Mine Expansion Project

Challenge:A major copper operation needed to increase primary crushed throughput by 25% without expanding their truck dump pocket footprint or compromising reliability in highly abrasive ore.Solution:The installation of a new series heavyduty gyratory crusher featuring our advanced concave system and highcapacity chamber design.Results: Achieved a sustained throughput increase of 28%. Liner life improved by an average of18%, contributing directly to meeting expanded production targets within planned maintenance windows.

Granite Aggregate Quarry Modernization

Challenge:A large quarry faced prohibitive downtime during concave liner changes on their aging primary crusher,scheduled every9 months,and struggled with inconsistent product sizing.Solution:Replacement with a modern gyratory crusher equipped with the Integrated Automatic Setting Regulation(ASR)and topservice concave system.Results:Liner change time reduced from44 hours to27 hours.Product consistency improved,variation in CSS reduced by70%,leadingto optimized secondary circuit performance.Financial payback was achieved in under22 months through productivity gains.

7.COMMERCIAL CONSIDERATIONS

Our heavyduty primary gyratory crushers are capital investments engineeredfor longterm total cost of ownership reduction.Commercial offerings are structured as follows:

Pricing Tiers:Capital pricing is modeldependent,based on size(gape)and selected configuration options.Equipment packages typically include the crusher,motors,Vbelts,lubrication system,and basic instrumentation

.Optional Features & Upgrades:These include advanced condition monitoring sensors( vibration,temperature),automated wear part measurement systems,dust suppression ring kits,and specialized liner metallurgiesfor specific ore types

.Service Packages:We offer tiered service agreements covering scheduled inspections,predictive maintenance support,and priority accessto technical specialists.Planned maintenance contracts can be structuredto fix annual operating costsfor critical wear components

.Financing Options:Flexible commercial terms are available includingstraight capital purchase,fleet leasing structures,and projectbased financing solutions tailoredto greenfield developmentsor major expansion projects

.8.FAQ

Q:What documentation is includedwiththe manufacturer certificate?
A:The formal manufacturer certificate attests thatthe equipment was designed,machined,and assembled tomeet all stated specifications.Itis supportedby mill test reportsfor major steel castingsand forgings,dimensional inspection reports,and functional test recordsfor assembled subsystems

.Q:Canyourgyratorycrusherbe integratedintoour existing PLC/plant control system?
A Yes.All units come standardwith modern control interfaces(typically Ethernet/IPor Modbus TCP).Our engineering team can provide necessary communication protocolsand points listsfor seamless integration intoyour wider plant SCADA network

.Q:Whatisthe typicallead timefrom orderto commissioning?
A Lead times varyby model complexityand current production scheduling.For standard configurations,target lead times range between10and14 months.This includes manufacturing,factory testing,and preparationfor shipment.Detailed schedulesare provided upon project initiation

.Q Howdoesthe automatic setting regulation impactproduct quality?
A The ASR system maintains adiscrete closedloop controlon themantle position.Field data shows this reduces CSS variationby over80%comparedtomanual methodsunder load.This resultsin amore consistentfeed sizefor secondaryand tertiary stages improving overall circuit stabilityand product yield

.Q Whattrainingis providedfor ourmaintenance crew?
A We provide comprehensive onsite training during commissioning covering normal operation routine inspections lockout/tagout proceduresand detailed stepbystep training formajor wear part replacement.Thisis supplementedby detailed service manualsand instructional videos

.Q Arewear parts interchangeablewith other OEMs'crushers?
A No Ourgyratorycrusheris designedwith proprietarygeometryand mounting systems tomaximize performance.Wear partsare notmechanically interchangeablewith thosefrom other manufacturersensuring optimal fit functionand longevityas intendedby ourdesign engineers

.Q Whatisthe expectedservice lifeforthemajor structural components?
A The main frame top shelland bottom shellare designed fora minimumservice lifeof30+yearsunder normal operating conditions when maintained accordingto our prescribed schedules.Thisis basedon finite element analysis(FEA)and historical performance datafrom earliergeneration unitsstill in operation