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 processing line. Common challenges include:
Excessive Downtime for Liner Changes: Traditional maintenance shutdowns for mantle and concave replacement can halt production for 2472 hours, costing tens of thousands in lost throughput.
Unplanned Stoppages from Tramp Iron: Inadequate protection from noncrushable material leads to costly damage, requiring immediate intervention and component replacement.
Inconsistent Feed & Product Size Distribution: Fluctuating feed material characteristics cause chokefeeding issues or cavity flooding, reducing throughput and increasing power consumption per ton.
High Operational & Maintenance Labor Costs: Frequent manual adjustments, lubrication system monitoring, and component wear inspections demand significant skilled labor hours.

Is your operation seeking a primary crusher solution engineered to deliver maximum uptime, lower costperton, and predictable performance in the face of these challenges?

2. PRODUCT OVERVIEW

A Gyratory Crusher is a heavyduty, continuousduty primary crushing machine designed for highcapacity applications in largescale mining and aggregate operations. Its core mechanism involves a gyrating mantle within a stationary concave, creating a progressive crushing cavity that reduces runofmine ore or shot rock to a manageable size for downstream conveying and processing.

Operational Workflow:
1. Feed Intake: Largesized material is directed into the top of the crusher via dump trucks, loaders, or a shovel.
2. Progressive Crushing: The eccentrically driven mantle gyrates within the concave, applying compressive force to reduce material size with each cycle.
3. Discharge: Crushed product exits through the bottom of the crushing chamber (the discharge opening) onto a conveyor belt for transport to the next stage.

Application Scope: Ideal for hightonnage (1,500+ TPH) hard rock mining (copper, iron ore, gold), large quarry operations, and major industrial mineral processing plants requiring primary reduction of abrasive materials.

Limitations: Not suitable for lowcapacity operations (<500 TPH) due to high capital cost. Requires significant foundational support and vertical height. Less effective for recycling or asphalt crushing where jaw crushers or impactors may be preferred.

3. CORE FEATURES

Patented Spider Design | Technical Basis: Multiarm, forged alloy steel construction with top shell attachment | Operational Benefit: Distributes load evenly across the main shaft and bearings, providing exceptional stability under shock loading from large feed material | ROI Impact: Extends bearing life by up to 40%, reducing major overhaul frequency and associated downtime costs.

Integrated Automatic Setting Regulation (ASR) System | Technical Basis: Hydraulic adjustment with realtime position sensors | Operational Benefit: Allows operators to adjust the crusher discharge setting remotely in minutes without stopping production, optimizing product size for changing downstream requirements | ROI Impact: Maintains optimal throughput and circuit efficiency; eliminates 48 hours of manual adjustment labor per change.

Lube System with Dual Coolers & Filtration | Technical Basis: Highflow circulation with temperature control and particulate filtration | Operational Benefit: Ensures consistent bearing temperature under peak loads; removes metallic wear particles from oil | ROI Impact: Prevents thermalrelated bearing failures; field data shows a 25% reduction in lube oil degradation rate, lowering consumable costs.

Manganese Steel Concave & Mantle Liners | Technical Basis: Workhardening austenitic manganese steel castings | Operational Benefit: Liners develop a hardened surface layer during operation that resists abrasion while maintaining core toughness against impact fractures | ROI Impact: Achieves industryleading wear life (measured in tons crushed), directly lowering costperton for wear components.

Tramp Iron Relief System | Technical Basis: Hydraulic cylinders support the main shaft assembly; pressure sensors detect uncrushable objects | Operational Benefit: Automatically opens the discharge setting to release tramp iron, then returns to original setting without stopping the crusher drive motor | ROI Impact: Prevents catastrophic damage; avoids unplanned downtime events that can exceed $100k in lost production per incident.

Chamber Profile Optimization | Technical Basis: Computermodeled nonchoking concave design with optimized nip angle | Operational Benefit: Promotes firstpass reduction at the top of the chamber and ensures steady material flow without bridging or erratic power draw | ROI Impact: Delivers up to 10% higher throughput compared to conventional profiles with identical motor power input.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Gyratory Crusher | Our Gyratory Crusher Solution | Advantage (% improvement) |
| : | : | : | : |
| Availability (Scheduled) | 9294% availability factor due to liner change downtime| 96%+ availability factor via quickchange liner systems & ASR| +34% more productive hours annually |
| Specific Energy Consumption| ~0.8 1.0 kWh/tonne crushed| ~0.7 0.85 kWh/tonne crushed via optimized kinematics| Up to 15% lower energy cost per ton |
| Wear Life Concaves (Abrasive Ore)| Life measured relative to baseline = 100%| Life measured relative to baseline = 130150%| +3050% longer service intervals |
| Time for CSS Adjustment| Manual adjustment requires 48 hour shutdown| Remote hydraulic adjustment in <15 minutes via ASR system| ~98% less downtime for adjustments |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 1,500 to over 12,000 tonnes per hour (TPH), depending on model size and feed material.
Motor Power: Electric drive motors ranging from 450 kW to over 1 MW (600 1,300 HP).
Feed Opening: Gape sizes from 1,000 mm up to 1,800 mm (approx. 40" to 72").
Discharge Setting Adjustment Range: Typically from 125 mm to 250 mm (5" to10"), adjustable via hydraulic system.
Main Frame & Shell Material: Fabricated from hightensile strength steel plate; critical areas feature wearresistant liners.
Main Shaft Material: Forged from highstrength alloy steel with precision machining.
Operating Temperature Range: Designed for ambient conditions from 40°C to +50°C (40°F to +122°F). Lube system includes heaters/coolers as required.
Dust Containment: Standard flanges provided for integration with dry dust suppression systems or water spray systems.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: A Tier1 copper operation needed to increase primary crushing capacity by over 30% within existing footprint constraints while managing highly abrasive sulfide ore that caused rapid liner wear.
Solution: Implementation of two highcapacity Gyratory Crushers featuring our optimized chamber profile and premium manganese liners.
Results: Achieved sustained throughput of 8 ,500 TPH per crusher. Liner life increased by 35%, extending changeout cycles from 6 months to over 8 months. Overall plant availability improved by 2 .5%.

Major Granite Quarry Complex

Challenge: Unpredictable feed blockiness led to frequent cavity choking events in existing primary crushers , causing circuit stoppages , excessive energy spikes , and premature component stress .
Solution : Installation of a single heavyduty Gyratory Crusher equipped with an advanced nonchoking concave design and an automated tramp iron relief system .
Results : Eliminated unplanned choking events . Power draw stabilized , reducing specific energy consumption by 12%. Production yield of spec base material increased due t o more consistent product gradation .

7 . COMMERCIAL CONSIDERATIONS

Pricing tiers are structured according t o crusher size , capacity ,and optional feature packages :
Base Model Range : Includes core crusher assembly , standard lubrication unit ,and basic instrumentation . Suitable f or standard duty cycles .
Performance Package : Adds Integrated ASR system , advanced condition monitoring sensors ,and quickchange liner kits . Recommended f or operations prioritizing flexibility .
Premium Service Package : Bundles equipment with extended warranty coverage , predictive maintenance analytics software subscription,and guaranteed OEM spare parts delivery terms .

Financing Options include capital purchase ,operational lease agreements,and throughputbased contracts where payments correlate directly w ith achieved production volume .

Service Packages range f rom basic technical support t o comprehensive onsite maintenance contracts managed b y factorytrained technicians .

8 . FAQ

Q : Can this gyratory crusher replace our existing primary jaw crusher without major modifications t o th e feed arrangement ?
A : While possible,the taller vertical profile typically requires reassessment o f dump pocket design an d feeder height .Our engineering team provides detailed layout studies t o evaluate retrofit feasibility .

Q : What i s th e typical installation an d commissioning timeline ?
A From delivery t o first ore,a standard project requires 8 12 weeks,following foundation readiness.This includes mechanical erection,lubrication an d hydraulic system commissioning,motor alignment,and noload/load testing .

Q How does th e automatic setting regulation impact final product shape ?
A The ASR adjusts th e closed side setting(CSS )t o control top size.It does not alter th e fundamental compressive breakage action,s o product shape(cubicity )remains consistent w ith gyratory crushing characteristics .

Q Are wear parts interchangeable w ith other OEM g y r atory crushers ?
A No.Critical wear components like concaves,mantles,and spider arm guards are designed specifically f or our chamber geometry an d mounting systems.They are not dimensionally interchangeable,preserving designed performance an d safety .

Q What training i s provided f or our operations an d maintenance teams ?
A We provide comprehensive onsite training covering safe operation,routine maintenance procedures,troubleshooting guides,and specific instruction on using th e ASR an d condition monitoring systems .

Q What i s your lead time f o r critical spare parts ?
A Our global logistics network targets 9 5 % availability f or critical rotating assembly spares exstock fr om regional service centers.Nonstandard parts have defined manufacturing lead times provided upon request .