1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? Key challenges in primary gyratory crusher operation directly impact your bottom line:
Excessive Downtime for Maintenance: Traditional spider arm and top shell designs require complex, timeconsuming procedures for wear part replacement, leading to production losses of several days.
Unplanned Stoppages from Tramp Iron: Inadequate protection mechanisms can result in catastrophic damage from uncrushable material, with repair costs exceeding hundreds of thousands and causing extended outages.
Inconsistent Throughput & Product Gradation: Worn or poorly designed crushing chambers fail to maintain optimal feed acceptance and product size control, bottlenecking downstream processes and reducing final product yield.
High Energy Consumption per Ton: Inefficient crushing action and excessive friction from outdated mechanical designs lead to unsustainable power costs, a major operational expenditure.

Is your operation equipped to overcome these challenges? The solution lies in a modern gyratory crusher engineered for reliability, efficiency, and lower total cost of ownership.

2. PRODUCT OVERVIEW: GYRATORY CRUSHER

A gyratory crusher is a primary compression crusher central to hightonnage mining and aggregate operations. It utilizes a fixed conical shell (concave) and a gyrating mantle mounted on an eccentric shaft to reduce large runofmine (ROM) feed material down to a conveyable size.

Operational Workflow:
1. Feed Acceptance: ROM material is fed into the top of the crusher via dump trucks, loaders, or a primary feeder, entering the gap between the mantle and concave.
2. Compressive Crushing: The mantle gyrates within the concave, applying compressive force to the rock particles against the stationary liners.
3. Progressive Reduction: Material is crushed continuously as it moves down through the chamber due to gravity and the crushing action.
4. Discharge: Crushed product exits at the bottom through the discharge opening (OSS), where it is transported via conveyor for secondary processing.

Application Scope & Limitations:
Scope: Ideal for highcapacity (1,000+ TPH) primary crushing of hard, abrasive ores (iron ore, copper ore) and large aggregate feed. Suited for stationary plant installations.
Limitations: Not designed for recycled concrete/asphalt or lowtonnage applications. Requires significant capital investment and a robust foundation. Feed size must be controlled within design parameters.

3. CORE FEATURES

Patented Top Service Design | Technical Basis: Simplified mechanical access from above | Operational Benefit: Enables liner changes and maintenance in 2448 hours versus 57 days | ROI Impact: Reduces planned downtime by over 60%, increasing annual available production time

Integrated Automatic Tramp Release System | Technical Basis: Hydraulic cylinders support the main shaft | Operational Benefit: Automatically lowers the main shaft to pass tramp iron, then resets without stopping | ROI Impact: Eliminates costly damage from uncrushables; prevents an average of 35 days of unplanned downtime annually

Optimized Crushing Chamber Profiles | Technical Basis: Computermodeled kinematics and wear simulation | Operational Benefit: Maintains consistent feed acceptance and product gradation throughout liner life | ROI Impact: Improves overall circuit throughput stability by 58% and extends liner service life by 1525%

HighPower Drive & Robust Eccentric Assembly | Technical Basis: Hightorque motor coupled with a forged alloy steel eccentric | Operational Benefit: Delivers consistent crushing force under peak loading conditions with minimal vibration | ROI Impact: Provides higher availability (>94%) and reduces stressinduced component failures

Centralized Automated Lubrication System | Technical Basis: Programmable PLCcontrolled lubrication to all critical bearings | Operational Benefit: Ensures optimal bearing temperature and health; provides diagnostic alerts | ROI Impact: Extends bearing service life by up to 30% and prevents lubricationrelated stoppages

StateoftheArt Control System (ICS) | Technical Basis: Realtime monitoring of power draw, pressure, temperature, and cavity level | Operational Benefit: Allows operators to optimize performance and receive predictive maintenance alerts | ROI Impact: Increases operational efficiency by 35% through precise control; enables conditionbased maintenance planning

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Older Gyratory Designs) | Modern Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Planned Maintenance Time (Spider Arm/Liners) | 120 168 hours | 48 72 hours with Top Service Design| 60% Reduction |
| Mechanical Availability (Annual) | 88 91%| >94% (documented field average)| 36% Increase |
| Liner Utilization (Tonnes/Liner KG)| Baseline| Optimized chamber design & materials| 1525% Improvement|
| Energy Consumption (kWh/tonne)| Baseline| Efficient drive & chamber kinematics| 510% Reduction |
| Tramp Iron Damage Events / Year| 0.5 1 event (avg.)| Nearzero with automatic system| >95% Reduction |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 1,500 to over 12,000 tonnes per hour (TPH), depending on model chamber selection and feed material.
Motor Power: Heavyduty squirrel cage induction motors ranging from 450 kW to over 1 MW.
Feed Opening: Gape sizes from 1,000 mm up to 1,800 mm for handling large ROM feed.
Main Frame & Concaves: Fabricated highstrength steel main frame; concaves available in manganese steel or composite alloy designs for specific abrasion/impact conditions.
Dimensions & Weight: Significant footprint; approximate installed weight ranges from 250 tonnes for smaller models to over 800 tonnes for largest units.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C with appropriate lubrication systems. Dust sealing is standard.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: A tierone copper operation needed to increase plant throughput by 25%. Their existing primary gyratory was a bottleneck with frequent liner change downtime exceeding one week.
Solution: Installation of a new highcapacity gyratory crusher featuring top service design and an automated tramp release system.
Results: Achieved sustained throughput increase of 28%. Planned maintenance time reduced by approximately five days per event. Zero unplanned downtime due to tramp metal in the first two years of operation.

Granite Aggregate Quarry Upgrade

Challenge: A quarry producing railway ballast faced inconsistent product gradation as liners wore, leading to excessive recirculating load in their secondary circuit.
Solution: Implementation of a midrange gyratory crusher with computeroptimized crushing chamber profiles linked to an advanced control system (ICS).
Results: Product gradation remained within specification throughout >90% of liner life. Recirculating load decreased by an average of 15%, reducing energy consumption in the secondary cone crushers.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Capital cost varies significantly based on size/capacity:
MidRange Units (6,000 TPH): For major greenfield or expansion projects in bulk mining.

Optional Features & Upgrades: Advanced wear monitoring systems; specialized liner alloys for specific ore types; upgraded filtration systems for extreme environments; remote diagnostics connectivity.

Service Packages: Tiered offerings include:
Basic Warranty & Parts Support
Planned Maintenance Agreements with guaranteed parts supply
FullPerformance Contracts covering parts AND labor with availability guarantees

Financing Options: Projectspecific financing through manufactureraffiliated programs can include leasetoown structures or extended payment terms aligned with project rampup milestones.

8. FAQ

Q1: Is this equipment compatible with our existing primary feeding system?
A compatibility review is standard during project engineering analysis based on your feeder type capacity hopper design We provide detailed interface specifications

Q2 What is the expected impact on our overall plant energy consumption?
Field data shows modern drives optimized chambers can reduce specific energy kWh tonne crushed by This contributes directly lower operating costs

Q3 Are there financing options available beyond standard purchase?
Yes we offer several commercial structures including operating leases long term payment plans tailored large capital projects Consult our commercial team details

Q4 How does implementation typically affect ongoing personnel training?
We provide comprehensive onsite operator maintenance training documentation ensure your team achieves proficiency safe efficient operation quickly minimize transition disruption

Q5 What are lead times typical delivery installation schedule?
Lead times vary model specification current demand but generally range months Detailed project schedule developed during pre order engineering phase account site preparation logistics commissioning