1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? Key challenges in gyratory crusher operations often include:

Unscheduled Downtime: Premature wear of critical components like mantles and concaves leads to failure, causing production halts that cost thousands per hour.
High Maintenance Complexity: Traditional designs require extensive labor hours for routine inspections and part changes, pulling skilled personnel from other critical tasks.
Inconsistent Product Gradation: Worn or poorly adjusted crushers produce offspec material, causing bottlenecks in downstream processing and reducing plant throughput.
Excessive Energy Consumption: Inefficient crushing chambers and outdated drive systems result in higher power draw per ton of processed material, directly impacting operating costs.
Safety Risks During Maintenance: The sheer size and weight of components pose significant hazards during liner changes and servicing.

Is your operation managing these recurring issues? The solution lies not just in a crusher, but in a highavailability system engineered for total cost of ownership.

2. PRODUCT OVERVIEW: HIGH QUALITY GYRATORY CRUSHER

Our High Quality Gyratory Crusher is a robust, primary crushing solution engineered for hightonnage, continuousduty applications in largescale mining and aggregate operations. It is designed to accept runofmine feed material and reduce it to a consistent product for secondary crushing or conveying.

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 the mantle attached, gyrates within the stationary concave liners. This compressive action breaks the rock against itself.
3. Product Discharge: Crushed material falls by gravity through the increasingly narrow chamber until it reaches the desired size and discharges from the bottom.

Application Scope & Limitations:
Scope: Ideal for highcapacity (5,000+ TPH) primary crushing of hard rock (granite, basalt, iron ore, copper ore), overburden, and similar abrasive materials. Suited for fixedplant installations.
Limitations: Not designed for recycled concrete/asphalt or lowtonnage operations. Requires significant foundational support and capital investment commensurate with its size and duty.

3. CORE FEATURES

Patented Concave Design | Technical Basis: Segmented, reversible liners with optimized profile | Operational Benefit: Extends service life by up to 30%, allows for staged replacement to maintain product size | ROI Impact: Reduces liner inventory costs and downtime events

Integrated Smart Sensing System | Technical Basis: Realtime monitoring of shaft position, pressure, temperature, and wear | Operational Benefit: Provides predictive maintenance alerts and prevents catastrophic failure | ROI Impact: Enables planned shutdowns, improving overall plant availability

Hydroset® Tramp Release & Setting Adjustment | Technical Basis: Hydraulic cylinders support the main shaft for automatic clearing and CSS adjustment under load | Operational Benefit: Operators can adjust product size remotely in minutes; system automatically releases tramp iron | ROI Impact: Maximizes uptime by eliminating lengthy manual adjustments and reducing stallrelated damage

HighEfficiency Drive System | Technical Basis: Direct gearless drive or lowloss Vbelt transmission with highinertia flywheel | Operational Benefit: Smoothes peak loads, reduces energy spikes by up to 15%, ensures constant crushing force | ROI Impact: Lowers specific energy consumption (kWh/ton) for direct operational savings

ServiceOptimized Top Shell & Mantle Design | Technical Basis: Simplified twopiece design with hydraulic separation assist | Operational Benefit: Reduces mantle changeout time by up to 50% compared to traditional threepiece designs | ROI Impact: Lowers labor costs per maintenance event and returns crusher to service faster

Lube System with Dual Coolers & Filtration | Technical Basis: Redundant cooling circuits with automated temperature control and particle filtration | Operational Benefit: Ensures consistent bearing temperature under varying ambient conditions; extends oil and bearing life | ROI Impact: Prevents costly bearing failures; reduces consumable (oil) replacement frequency

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Availability (Scheduled Operating Time) | 92 94% | 96%+ (with Smart Sensing & Service Design)| >2% Improvement |
| Liner ChangeOut Time (Mantle/Concaves)| 24 36 hours| <18 hours average| Up to 50% Reduction |
| Specific Energy Consumption (kWh/tonne)| Varies by rock type| Field data shows 812% reduction| Direct OPEX Savings |
| Mean Time Between Failure (MTBF) Critical Bearings| ~18 months| >24 months typical service life| Extended Component Life |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2,000 to over 12,000 metric tons per hour (MTPH), depending on model size and feed material.
Motor Power: Heavyduty motors from 450 kW to over 1 MW (600 1,400 HP).
Feed Opening: Gape sizes from 1,000 mm to 1,500 mm (approx. 40” to 60”).
Main Frame & Shell Fabrication: Constructed from hightensile strength steel plate with stressrelieved welds; critical areas feature additional wear protection.
Main Shaft: Forged alloy steel core with precisionmachined mounting surfaces.
Dimensions & Weight: Varies significantly by model; largest models can exceed 15 meters in height and weigh over 400 tonnes sans feed hopper/discharge conveyor.
Ambient Operating Range: Designed for reliable operation from 40°C to +50°C (40°F to +122°F) with appropriate lube oil specifications.

6. APPLICATION SCENARIOS

Copper Mine Expansion – Throughput Constraint

Challenge: A major copper operation needed to increase plant throughput by 25% but was constrained by their existing primary crusher’s capacity and frequent linerrelated downtime.
Solution: Implementation of a largecapacity High Quality Gyratory Crusher featuring the patented concave design and Smart Sensing system.
Results: Achieved a sustained throughput increase of 28%. Predictive alerts reduced unplanned stoppages by an estimated 60 hours annually. Liner life improved by an average of 22%, lowering costperton for wear parts.

Granite Aggregate Quarry – Product Consistency & Safety

Challenge: A quarry faced inconsistent product gradation from their aging primary crusher leading to secondary circuit bottlenecks. Manual setting adjustments were timeconsuming and posed safety risks.
Solution: Installation of a midrange gyratory crusher equipped with the Hydroset® system for remote adjustment.
Results: Product gradation consistency improved significantly (+/5% on target size). CSS adjustments are now completed in under five minutes from the control room instead of four hours manually. This enhanced both safety protocol compliance and overall circuit stability.

7. COMMERCIAL CONSIDERATIONS

Our High Quality Gyratory Crushers are offered as capital equipment solutions structured around longterm value.

Pricing Tiers: Based on size/capacity (e.g., MkI through MkIV series). Pricing includes core crusher assembly with motor drive base frame lubrication system motor(s) Vbelts if applicable guards
Optional Features / Packages:

Performance Package: Includes Smart Sensing System advanced automation controls
Service Package: Includes specialized tooling kits hydraulic jacks installation supervision
Wear Parts Contract: Guaranteed liner life performance based on your specific ore characteristics with fixed costperton pricing

Service Packages:
Commissioning Support: Onsite technical supervision during installation startup
Planned Maintenance Agreements: Scheduled inspections parts discounts priority technical support
Operator Training Programs: Comprehensive training on operation maintenance troubleshooting

Financing Options:
We work with accredited partners to offer flexible commercial structures including capital lease operating lease or projectbased financing terms typically ranging from three seven years subject to credit approval

FAQ SECTION

Q1 How do I determine if this gyratory crusher is compatible with my existing plant layout feed system?
A detailed dimensional drawing foundation plan interface points will be provided during the quotation process Our engineering team can conduct a site integration review based on your existing conveyor positions feed hopper design electrical supply infrastructure

Q2 What is the expected impact on my overall plant efficiency?
Field data shows that improved reliability consistent product gradation typically lead downstream process stability You can expect reductions in secondary circuit surges screening inefficiencies leading higher overall plant availability We provide throughput modeling based your specific ore characteristics

Q3 What are typical lead times delivery?
For standard models lead times range six nine months from order placement final factory acceptance testing Custom configurations may require additional engineering time Expedited options may be available subject manufacturing schedule component supply chain status

Q4 What commercial terms warranty are standard?
Standard terms include FOB manufacturing facility Warranty covers defects materials workmanship period months from commissioning date hours whichever comes first Wear parts liners consumables covered under separate performancebased agreements Extended warranty options available purchase

Q5 How does implementation work? Do you provide installation support?
The crusher supplied as major assemblies requiring field bolting connection Implementation scope defined contract We strongly recommend our supervised installation service package which includes technical oversight alignment checks commissioning assistance ensure optimal performance startup