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 downstream process. Common challenges with traditional gyratory crushers include:

Excessive Downtime for Maintenance: Frequent, lengthy liner changes and unexpected mechanical failures halt production for days, directly impacting tonsperhour metrics and revenue.
High Operational & Energy Costs: Inefficient crushing chambers and outdated drive systems consume excessive power per ton of material processed, while rapid wear part consumption drives up costperton figures.
Inconsistent Product Size & Capacity: Fluctuations in feed material can lead to poor setting control, resulting in offspec product that stresses secondary crushers and reduces overall plant throughput.
LaborIntensive Monitoring & Adjustment: Reliance on manual checks for wear and performance optimization increases labor costs and the risk of human error leading to catastrophic damage.

Is your operation equipped to overcome these challenges? The solution lies in a fundamentally redesigned ODM gyratory crusher engineered for the demands of modern, highvolume mineral processing.

2. PRODUCT OVERVIEW: ODM Gyratory Crusher

The ODM Gyratory Crusher is a heavyduty, primary crushing machine designed for the first stage of reducing runofmine ore or quarry rock. It operates on the principle of a gyrating mantle within a concave crushing chamber, creating a progressive crushing action ideal for hightonnage, abrasive materials.

Operational Workflow:
1. Feed Intake: Largesized feed material is directed into the top of the crusher’s deep chamber via dump trucks, loaders, or a primary feeder.
2. Progressive Crushing: The eccentrically gyrating mantle continuously compresses material against the stationary concaves, breaking it into smaller fragments through a combination of impact and attrition.
3. Discharge: Crushed product exits through the bottom discharge opening (OSS), with size primarily controlled by the closedside setting of the mantle.

Application Scope & Limitations:
Scope: Optimized for highcapacity (2,000+ tph) primary crushing of hard rock (granite, basalt), iron ore, copper ore, and gold ore. Suitable for both stationary plants and semimobile installations.
Limitations: Not designed for recycled concrete/asphalt or lowabrasion materials better suited for jaw crushers. Requires a stable, reinforced concrete foundation and significant vertical space for installation and maintenance access.

3. CORE FEATURES

Patented ASRi+ Automation System | Technical Basis: Adaptive closedside setting control via realtime pressure & power monitoring | Operational Benefit: Maintains consistent product size and automatically compensates for liner wear; protects from mechanical overload | ROI Impact: Up to 10% increase in throughput; prevents costly downtime from packing or overload events

Top Service Design | Technical Basis: All serviceable components accessible from above | Operational Benefit: Enables safer, faster liner changes and maintenance without personnel working beneath suspended loads | ROI Impact: Reduces scheduled maintenance downtime by up to 30% compared to bottomservice designs

DualPiston Hydraulic Ram Adjustment & Clearing | Technical Basis: Two hydraulic cylinders control mainshaft position for setting adjustment and tramp iron release | Operational Benefit: Allows precise CSS adjustment under load and rapid clearing of stalled cavities in minutes | ROI Impact: Maximizes crusher availability; eliminates hourslong clearing procedures common with spidermounted systems

HighPrecision SpiralBevel Drive System | Technical Basis: Computeroptimized gear geometry with forcedfeed lubrication | Operational Benefit: Transmits power more efficiently with less vibration and heat generation than traditional designs | ROI Impact: Documented 57% reduction in specific energy consumption (kWh/ton); extends gearset service life

Integrated Main Shaft Position Sensor | Technical Basis: Continuous monitoring of mainshaft vertical position relative to top shell | Operational Benefit: Provides operators with realtime data on liner wear rates for predictive maintenance scheduling | ROI Impact: Enables optimal liner utilization before changeout; improves planning accuracy for parts inventory

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | ODM Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Liner ChangeOut Time (Major) | 48 72 hours | 36 48 hours (Top Service) | ~30% reduction in downtime |
| Specific Energy Consumption (kWh/t) Varies by material. Baseline = 100%| Baseline = 100%| Average reduction to ~9395%| 57% improvement in energy efficiency |
| Availability (Scheduled Maintenance) Industry average excludes unscheduled stops.| ~9495% availability| Target >96% availability| >1 percentage point increase |
| Wear Life Consistency Liner life varies widely; metric is predictability.| High variance due to manual adjustment.| Low variance via ASRi+ automation.| Up to 15% more predictable life |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Modeldependent, from 2,000 to over 10,000 metric tons per hour (tph).
Motor Power Requirements: Typically 300 kW to over 800 kW (400 HP 1,000+ HP), depending on model size and duty.
Feed Opening Range: Gape sizes from 800mm to over 1,500mm.
Key Material Specifications:
Mainframe & Top Shell: Highstrength fabricated steel with stressrelieved construction.
Concaves & Mantle Core: Manganese steel castings (14%18% Mn), optional alloy overlays available.
Main Shaft & Eccentric Sleeve Forged alloy steel with precision machining.
Physical Dimensions / Footprint: Varies significantly by model; requires detailed civil engineering drawings for foundation planning.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C (4°F to +113°F). Dust seals protect internal components in highdust environments.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge A major South American copper mine needed to increase primary crushed throughput by 25% without expanding their existing crusher footprint or foundation. Their legacy equipment could not achieve higher capacity without risking reliability.
Solution Installation of a single highcapacity ODM gyratory crusher featuring the ASRi+ system was selected over installing two smaller units.
Results The new crusher achieved a sustained throughput increase of 28%. The automated control stabilized product size fed to the SAG mills, contributing to a measured overall circuit efficiency gain of approximately 8%.

Granite Quarrying Operation

Challenge A North American aggregate producer faced unsustainable costperton due to weekly manual CSS checks/ adjustments on their primary gyratory crusher leading to inconsistent product yield and high labor costs.
Solution Retrofit installation of an ODM ASRi+ automation package onto their existing gyratory structure was implemented during scheduled maintenance shutdown period .
Results Product yield within target specification improved from an average of ~88% consistently above . Labor hours dedicated daily manual adjustments were eliminated entirely resulting direct annual labor savings .

7 COMMERCIAL CONSIDERATIONS

Equipment pricing structured according model size capacity tiered options:
Tier Basic models include standard drive system core automation Tier Advanced includes full ASRi+ automation package advanced wear monitoring sensors Tier Premium includes custom alloy liners extended warranty coverage initial commissioning support

Optional Features Available:
Dust suppression ring packages
Advanced predictive analytics software integration
Specialized liner profiles specific material types e.g., highly abrasive taconite
Semimobile skid base design

Service Packages:
Preventive Maintenance Plans scheduled inspections parts discounts
OnSite Technical Support dedicated engineer days per year
Emergency Parts Kits curated critical spares held onsite reduce lead time

Financing Options:
Capital lease operating lease structures available through partners
Project financing considered largescale greenfield expansions

8 FAQ

What level site preparation required installation?
Installation requires substantial reinforced concrete foundation designed specific model load dynamics detailed geotechnical report Our engineering team provides complete foundation drawings specifications part scope supply .

How does ASRi+ system integrate with existing plant DCS/SCADA?
The automation system communicates industrystandard protocols Modbus TCP/IP Profinet allowing seamless data exchange your central control room minimal integration effort required .

What typical lead time delivery commissioning new unit?
Lead times vary based model complexity current manufacturing schedule Typically range months order placement shipment Commissioning supervised our engineers typically requires weeks depending site readiness .

Are wear parts interchangeable other manufacturer models?
No Our concaves mantles other wear components designed proprietary chamber geometry metallurgy ensure optimal performance interchangeability not recommended would compromise throughput efficiency potentially void warranties .

What financing options available purchase?
We work several international equipment finance institutions offer range solutions including capital leases operating leases tailored balance sheet requirements Projectspecific financing can be explored large capital projects .

Can older gyratory crushers retrofitted your automation technology?
In many cases yes Our team can conduct feasibility study assess compatibility your existing mainframe drive system Retrofit projects offer costeffective path significant performance improvements .