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 with their primary gyratory crushers, including:

Excessive Downtime for Maintenance: Traditional designs require lengthy, complex procedures for wear part replacement and chamber clearing, leading to production losses that can exceed 100 hours annually.
Unplanned Stoppages from Tramp Iron: Noncrushable material entering the chamber can cause significant damage, resulting in catastrophic component failure, emergency shutdowns, and sixfigure repair bills.
Inconsistent Throughput & Product Size: Worn or poorly configured crushers fail to maintain target product gradation, causing bottlenecks in downstream processes and reducing overall plant efficiency by 515%.
High Operational & Energy Costs: Inefficient crushing chambers and highfriction components lead to specific energy consumption (kWh/tonne) figures that directly impact your bottom line.

Is your current primary crusher a reliable asset or a recurring source of cost and delay? The solution lies in selecting a gyratory crusher engineered not just for capacity, but for total operational cost control.

2. PRODUCT OVERVIEW: GYRATORY CRUSHER

A gyratory crusher is a stationary compressive crushing machine central to hightonnage mining and aggregate operations. It is designed for primary crushing of runofmine ore or blasted quarry rock into a size suitable for secondary processing.

Operational Workflow:
1. Feed Intake: Large feed material (up to 1.5m in size) is delivered via haul trucks or loaders into the topmounted feed hopper.
2. Compressive Crushing: The central mantle gyrates within the concave liners, applying progressive compressive force to reduce material by pinching and bending.
3. Discharge: Crushed product exits through the discharge opening at the bottom of the crushing chamber, its size determined by the closedside setting (CSS).

Application Scope & Limitations:
Scope: Ideal for highcapacity (1,000 10,000+ tph) primary crushing applications in hard rock mining (iron ore, copper, gold), largescale aggregate quarries, and industrial mineral processing.
Limitations: Not suitable for abrasive recycling materials with high metal content. Requires a stable concrete foundation and significant vertical space for installation. Lower initial mobility compared to mobile jaw crusher setups.

3. CORE FEATURES

Patented Concave & Mantle Profiles | Technical Basis: Computeroptimized chamber geometry based on DEM (Discrete Element Modeling) | Operational Benefit: Delivers consistent product gradation throughout the liner life with reduced risk of bridging | ROI Impact: Maintains downstream circuit efficiency, improving overall plant yield by an estimated 38%.

Integrated Automatic Tramp Release System | Technical Basis: Hydraulic cylinders support the mainshaft; pressure sensors detect uncrushable material | Operational Benefit: Automatically lowers the mainshaft to pass tramp iron, then resumes position without stopping | ROI Impact: Prevents damageinduced downtime; field data shows a reduction of over 90% in tramp ironrelated stoppages.

TopService Design (TSD) | Technical Basis: All major service components accessible from above via a central service platform | Operational Benefit: Enires concaves and mantles can be replaced in 4872 hours versus 710 days with traditional designs | ROI Impact: Reduces planned maintenance downtime by approximately 70%, translating to thousands of additional production hours over the crusher's life.

HighStrength Alloy Steel Mainframe & Eccentric | Technical Basis: Forged from highintegrity alloy steel with finite element analysis (FEA) validation | Operational Benefit: Provides exceptional durability under extreme cyclical loading with minimal deformation | ROI Impact: Extends structural service life beyond 30 years, protecting your longterm capital investment.

Direct Drive & Variable Speed Capability | Technical Basis: Lowspeed synchronous motor connected directly to the eccentric via a coupling | Operational Benefit: Eliminates Vbelt maintenance; variable speed allows optimization of throughput and product shape for different feed materials | ROI Impact: Increases energy transmission efficiency by up to 5% versus traditional drives and provides operational flexibility.

Centralized Automated Lubrication System | Technical Basis: Programmable system delivering precise oil volume and pressure to all critical bearings | Operational Benefit: Ensures optimal bearing temperature and health, providing early warning diagnostics | ROI Impact: Extends bearing lifecycles by up to 40% and prevents costly bearing failures.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Availability (Annual) | 92 94% | 96%+| >2% improvement |
| Specific Energy Consumption| Varies by ore; baseline = 100%| 9095% of baseline| 510% reduction in kWh/tonne |
| Liner Changeout Time (Full Set) | 7 10 days| 2 3 days| ~70% faster |
| Mean Time Between Failure (MTBF) Major Components| Industry average established| +35% longer MTBF| Significant reduction in unplanned events |
| Throughput Consistency (Liner Life Variance)| +/15% from newtoworn| +/8% from newtoworn| More stable feed for downstream processes |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Available in multiple sizes with rated capacities from 1,200 to over 12,000 tonnes per hour, based on standard crushable ore density.
Power Requirements: Drive motor ratings from 300 kW up to 1,200 kW, dependent on model and application. Electrical supply must match motor specifications.
Material Specifications: Mainframe constructed from hightensile carbon steel plate. Concave and mantle liners available in premium manganese steel alloys or optional composite materials for specific abrasion/impact conditions.
Physical Dimensions & Weight: Feed opening diameters range from 800mm to 1,500mm. Total installed height ranges from 6m to 10m. Machine weights range from 150 to over 450 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust seals are rated for severe environments. Can be equipped with housing heaters or cooling systems as required.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: A major copper operation needed to increase plant throughput by 25%. The existing primary gyratory was a bottleneck with frequent liner changeover delays exceeding one week.
Solution: Implementation of a new highcapacity gyratory crusher featuring TopService Design and optimized chamber profiles.
Results: Achieved sustained throughput of 8,500 tph. Liner changeouts were completed in under three days each cycle. The project met its expansion CAPEX goals with an estimated payback period of under three years based on increased production.

Granite Aggregate Quarry Modernization

Challenge: An aging primary crusher led to unpredictable product gradation causing inefficiencies in secondary/tertiary stages and high energy costs per ton.
Solution: Replacement with a modern gyratory crusher equipped with variable speed drive and automated control system interfacing with the plant SCADA.
Results: Product consistency improved, reducing recirculating load in downstream cones by an average of 18%. Overall plant energy consumption per ton of saleable aggregate decreased by 9%.

7. COMMERCIAL CONSIDERATIONS

Equipment Pricing Tiers:
Base Configuration (Standard Duty): Includes core crusher assembly drive motor lubrication system basic instrumentation
Premium Configuration Heavy Duty): Includes upgraded liners enhanced automation package advanced condition monitoring sensors extended warranty
Turnkey SkidMounted Solutions Available

Optional Features:
Advanced predictive maintenance software integration
Special alloy liner packages for highly abrasive ores
Remote diagnostic capability
Automated setting adjustment system

Service Packages:
1 Bronze Plan): Includes scheduled inspections parts discount
2 Silver Plan): Adds annual preventative maintenance labor coverage
3 Gold Plan): Comprehensive coverage including planned liner changeouts guaranteed response times

Financing Options:
Flexible commercial structures are available including capital purchase finance lease or longterm performancebased crushing contracts tailored project financing

FAQ

What are the foundation requirements?
A reinforced concrete foundation designed per supplied load drawings is required typically involving several hundred cubic meters concrete Installation must be performed certified contractors

How does this integrate with our existing SAG mill feed conveyor system?
Our engineering team will provide detailed interface drawings belt loading data Our control systems are designed communicate using standard industrial protocols Modbus TCP/IP Profinet

What is the expected operational lifespan?
The mainframe shell eccentric assembly are designed minimum year lifespan Wear components concaves mantles have service life dependent application typically ranging months several years

Do you offer liner profiling services optimize our specific ore type?
Yes we provide proprietary wear analysis modeling recommend optimal chamber profiles maximize throughput product shape minimize cost per ton crushed This included premium service packages

What are payment terms typical delivery lead time?
Standard terms progress payment milestone Final payment prior shipment Lead times vary model complexity Typically range months order confirmation ex works Expedited options may available