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: excessive maintenance downtime for mantle and concave changes, high energy consumption per ton of processed material, and inconsistent feed opening performance leading to bottlenecks. Unplanned stoppages for repairs can cost tens of thousands per hour in lost production. Furthermore, premature wear on critical components directly increases your costperton metric.

How do you achieve higher throughput without a proportional increase in energy costs? Can you extend liner life to align maintenance with planned shutdowns? Is your primary crusher a reliable asset or a recurring source of operational risk? Addressing these questions is fundamental to securing a competitive edge in today’s market.

2. PRODUCT OVERVIEW: HEAVYDUTY PRIMARY GYRATORY CRUSHER

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

Operational Workflow:
1. Feed Acceptance: Large feed material is directed into the top of the crusher’s deep, nonchoking crushing chamber.
2. Gyratory Crushing Action: The main shaft assembly, with its mounted mantle, gyrates within the stationary concave liners. This eccentric motion applies compressive force to the rock.
3. Progressive Reduction: Material is crushed continuously as it travels down through the chamber, reduced in size at each point until it meets the desired discharge setting.
4. Discharge: The crushed product exits through the bottom of the crusher, ready for conveyor transport to secondary crushing or stockpiling.

Application Scope & Limitations:
Scope: Ideal for highcapacity (1,500+ tph) primary crushing of hard rock (granite, basalt, iron ore, copper ore), overburden, and shot limestone. Suited for fixedplant installations.
Limitations: Not designed for portable plants or recycling applications with significant tramp metal. Requires a stable concrete foundation and significant headroom for installation and maintenance.

3. CORE FEATURES

Patented Concave Design | Technical Basis: Segmented, reversible liners with optimized profile | Operational Benefit: Enables faster liner changes by 40% and allows use of both sides for extended service life | ROI Impact: Reduces labor costs per changeout and decreases liner inventory expenditure

Integrated Intelligent Control System | Technical Basis: Realtime monitoring of power draw, pressure, and eccentric throw | Operational Benefit: Automatically regulates feed rate to prevent overloads and optimizes cavity level for maximum throughput | ROI Impact: Protects against costly mechanical damage events and improves energy efficiency by up to 8%

Spiderless Top Shell Design | Technical Basis: Eliminates traditional spider arms through a reinforced rimandhub structure | Operational Benefit: Removes potential slurry pooling points and provides unobstructed feed opening | ROI Impact: Reduces corrosionrelated maintenance and maximizes feed acceptance capacity

Hydroset™ Tramp Release & Setting Adjustment | Technical Basis: Hydraulic cylinders support the main shaft for precise control | Operational Benefit: Allows operators to adjust crusher gap settings under load and automatically release tramp iron | ROI Impact: Minimizes downtime for product size changes and prevents catastrophic damage from uncrushables

HighTorque DirectDrive System | Technical Basis: Lowspeed synchronous motor coupled directly to the eccentric assembly | Operational Benefit: Delivers constant crushing force across the entire stroke with higher mechanical efficiency than Vbelt drives | ROI Impact: Lowers specific energy consumption (kWh/ton) and reduces drive system maintenance

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner ChangeOut Time (Major) | 48 72 hours | 24 36 hours | ~50% faster |
| Specific Energy Consumption (kWh/ton) Baseline = X kWh/t| X kWh/tonne| X 0.92 kWh/tonne| Up to 8% lower |
| Availability (Scheduled & Unscheduled) | 92 94% annual average| >96% annual average| >2 percentage points higher |
| Feed Opening Acceptable Fines Content (<100mm)| Limited to ~1015% before packing risk| Handles up to ~25% without choking| Significant flexibility in feed blend management |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 1,500 to over 12,000 metric tons per hour (tph), dependent on model selection and material characteristics.
Power Requirements: Main drive motors from 450 kW up to 1 MW+. Complete system includes dedicated power for lubrication and hydraulic units.
Material Specifications: Main frame constructed from highintegrity cast steel; concaves and mantles available in premium manganese steel alloys; wear surfaces feature hardened steel bushings.
Physical Dimensions (Typical Large Model): Total height ~79 meters; installed weight ranges from ~250 to over 600 metric tons excluding feed hopper/discharge conveyors.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust sealing systems are rated for continuous operation in highdust environments.

6. APPLICATION SCENARIOS

Copper Mine Expansion, South America

Challenge: A major expansion required primary crushing capacity exceeding 8,000 tph of abrasive copper porphyry ore. The existing plant suffered from frequent concave cracking events causing unplanned downtime.
Solution: Installation of two largecapacity gyratory crushers featuring the patented spiderless top shell design and intelligent control system.
Results: Achieved sustained throughput of 8,400 tph. The robust top shell design eliminated stressrelated liner failures observed previously. Intelligent controls optimized load distribution across both units.

Granite Aggregate SuperQuarry, North America

Challenge: High operating costs driven by frequent manual crusher setting adjustments for different product grades and high energy consumption per ton.
Solution: Retrofit of an existing primary gyratory crusher with a modern Hydroset™ system and directdrive motor upgrade.
Results: Crusher gap adjustments reduced from hours to under ten minutes via remote console control. The directdrive system lowered specific energy consumption by approximately seven percent annually.

7. COMMERCIAL CONSIDERATIONS

Our gyratory crushers are offered under a tiered pricing structure based on size/capacity requirements:
Standard Duty Series: For capacities up to ~4,000 tph; includes core features like Hydroset™ control.
Heavy Duty Series: For capacities from ~4,000 – ~8 ,000 tph; adds enhanced monitoring systems as standard.
Super Heavy Duty Series: For ultrahighcapacity applications exceeding ~8 ,000 tph; includes full intelligent automation package.

Optional features include advanced predictive analytics software integration , specialized alloy liners for specific abrasion/corrosion conditions ,and automated lubrication systems .

We offer comprehensive service packages:
1 . Planned Maintenance Agreement: Scheduled inspections , parts discounts .
2 . Performance Guarantee Package: Includes guaranteed availability , throughput ,and liner life metrics .
3 . FullScope Lifecycle Contract: Covers all parts , labor ,and field service support .

Financing options include capital purchase ,operating lease structures ,and projectspecific financing solutions tailored for large capital expenditures .

8 . FAQ

Q1 : Is this gyratory crusher compatible with my existing secondary crushing circuit or SAG mill feed preparation ?
A1 : Yes . Our engineering team will review your target product size distribution ( PSD )to ensure optimal compatibility with your downstream processes .

Q2 : What is the expected impact on my plant ’s overall electrical load ?
A2 : While individual motor sizes are significant ,the improved specific energy consumption often leads to lower overall kWh /ton processed compared to older technology .A detailed load analysis is part of our pre sales proposal .

Q3 : How does your commercial offering handle long lead time components ?
A3 : Critical spare parts like main shaft assemblies are included in strategic stocking programs at our global service centers .Service agreements can guarantee parts availability within specified timeframes .

Q4 : What training is provided for our operations team ?
A4 : We provide comprehensive onsite training covering normal operation ,routine maintenance procedures ,and basic troubleshooting using our control system interfaces .

Q5 : Can we retrofit some of these features onto our existing older model gyratory crushers ?
A5 : Select upgrades such as modern control systems or new concave designs may be available as retrofit kits .Feasibility depends on your machine ’s model age condition ;an audit can determine scope .

Q6 : What are typical payment terms ?
A6 : Standard terms involve progress payments tied major manufacturing milestones shipment commissioning Custom terms may be structured based on project financing requirements .

Q7 How do you validate performance claims before purchase ?
A7 We provide extensive reference site contacts arrange site visits share anonymized operational data reports from similar installations Third party test reports on component durability are also available