1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable throughput crippling your gold processing profitability? The primary crushing stage sets the tone for your entire recovery circuit, and inefficiencies here cascade into significant financial losses. Consider these common challenges:
High Downtime for Maintenance: Frequent liner changes and unplanned repairs in your primary crusher halt your entire milling circuit, costing thousands per hour in lost production.
Inconsistent Feed Size Reduction: Variable ore hardness leads to fluctuating discharge sizes, overloading your SAG mill or secondary crushers and reducing overall plant efficiency by 1525%.
Excessive Energy Consumption: An inefficient or improperly sized primary crusher can be the single largest consumer of power in your comminution circuit, directly eroding profit margins.
Premature Wear Part Failure: Abrasive gold ores, particularly those with high silica content, can devastate standard manganese steel, leading to unsustainable consumable costs and contamination risks.

Is your current primary crushing solution a reliable asset or a constant source of bottleneck and cost? The right heavyduty jaw crusher is not just equipment; it is the foundational investment for predictable, lowcost tonnage.

2. PRODUCT OVERVIEW: HEAVYDUTY JAW CRUSHER FOR PRIMARY GOLD ORE REDUCTION

This product line comprises a range of robust, stationary and modular jaw crushers engineered specifically for the rigorous duty of primary gold ore crushing. Designed to accept runofmine (ROM) feed directly from the mine haul truck dump pocket, these machines provide the first critical size reduction.

Operational Workflow:
1. ROM Ore Intake: Direct dump from haul trucks (up to 1.5m lumps) into a vibrating grizzly feeder (optional) which scalps out fine material.
2. Primary Crushing: Ore is gripped and crushed between a fixed and a mechanically actuated moving jaw plate, utilizing compressive force.
3. Discharge & Conveyance: Crushed product (typically reduced to 150250mm) is discharged onto a main conveyor belt for transport to the next stage of processing (SAG mill or secondary crushing).

Application Scope: Ideal for hard rock gold ores (lode deposits), including sulphidebearing ores. Suitable for both greenfield installations and retrofit upgrades in existing CIP/CIL plants.

Limitations: Not designed for wet, sticky ores without prior screening/scalping. Maximum feed size is determined by modelspecific gape dimensions.

3. CORE FEATURES

Deep Crushing Chamber & Aggressive Nip Angle | Technical Basis: Optimized kinematics design | Operational Benefit: Increases capacity by up to 10% versus conventional designs and ensures positive bite on slabby material | ROI Impact: Higher throughput per installed horsepower reduces costpertonne

Hydraulic Toggle & Adjustment System | Technical Basis: Replaceable hydraulic cylinder for tramp iron relief and closedside setting (CSS) adjustment | Operational Benefit: Enables quick clearing of blockages without manual disassembly; allows remote CSS adjustment for optimal product size control | ROI Impact: Reduces downtime from blockages by over 80% and maintains consistent product gradation

Quenched & Tempered Alloy Steel Jaw Plates | Technical Basis: Proprietary metallurgy with high chrome content | Operational Benefit: Provides 3050% longer service life in abrasive silica gold ores compared to standard manganese steel | ROI Impact: Lowers costpertonne for wear parts and reduces frequency of hazardous liner changeout tasks

Unitized Base Frame & Spherical Roller Bearings | Technical Basis: Singlepiece fabricated base and oversized bearing housings | Operational Benefit: Eliminates misalignment issues; bearings are rated for extreme loads and contaminant exclusion | ROI Impact: Ensures longterm mechanical reliability with >95% operational availability

PLCBased Automation Interface | Technical Basis: Integrationready control system with standard Modbus protocol | Operational Benefit: Allows monitoring of power draw, CSS, and bearing temperature; enables automated load regulation via feeder control | ROI Impact: Prevents costly overload damage and optimizes energy use through smart load management

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Average | Our HeavyDuty Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Scheduled Runtime) | 9092% | 96%+ | +46% |
| Wear Life (Jaw Plates Silica Ore) | 120,000 tonnes | 180,000 tonnes (projected) | +50% |
| Specific Energy Consumption (kWh/tonne) Baseline Dependent Up to 12% Reduction via optimized kinematics & load management |
| Tramp Iron Clearing Time Major blockage requiring dismantling ~10 minutes via hydraulic toggle 80% downtime |

5. TECHNICAL SPECIFICATIONS

Capacity Range: 500 2,500 tonnes per hour (dependent on feed gradation and material characteristics).
Feed Opening (Gape): From 1,070mm x 760mm (42" x 30") up to 1,500mm x 1,200mm (59" x 47").
Power Requirement: Driven by 110kW to 375kW (150HP to 500HP) electric motors with Vbelt transmission.
Material Specifications: Main frame fabricated from highstrength steel plate; jaw plates available in multiple alloys including standard manganese or premium abrasionresistant alloy.
Physical Dimensions (Typical Model): Approx. Length: 7m Width 3m Height 3m Weight 55,000kg
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C Dust suppression spray bars are standard

6. APPLICATION SCENARIOS

Hard Rock Gold Mine Expansion Challenge A West African operation faced bottlenecks after increasing haul truck size ROM ore exceeded the capacity of their existing primary crusher causing frequent plugging Solution Installation of a larger gape heavyduty jaw crusher with an integrated vibrating grizzly feeder to scalp fines ahead of the crushing chamber Results Achieved design throughput of 1 800 tph consistently Reduced unscheduled downtime related to feeding by 70%

Retrofit in Aged Processing Plant Challenge A South American plant suffered from weekly shutdowns for manual jaw plate adjustment and excessive energy costs due to an inefficient 40yearold crusher Solution Retrofit replacement with a modern heavyduty jaw crusher featuring hydraulic adjustment and an automated lubrication system Results Energy consumption per crushed tonne fell by 9 Wear part changeout time reduced from 16 hours to 8 hours due to improved access design

7 COMMERCIAL CONSIDERATIONS

Our heavyduty jaw crushers are offered in three primary tiers:

Standard Duty Model: For consistent moderateabrasion ores Includes core features like unitized frame spherical roller bearings
HighAbrasion Model: Includes premium alloy jaw plates as standard upgraded liners on cheek plates extended warranty on bearings
Fully Modular SkidMounted Package: Includes crusher motor drive vbelt guards feeder discharge conveyor prewired PLC panel Reduces onsite installation time by up to 60%

Optional features include automated grease lubrication systems advanced wear monitoring sensors dust encapsulation kits

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements with guaranteed parts availability Financing options including leasetoown capital equipment loans are available through our partners

8 FAQ

Q What if my gold ore is wet and clayey?
A While designed for hard rock we recommend pairing the crusher with a robust vibrating grizzly feeder or scalper screen to remove fines ahead of the crushing chamber This prevents packing in the lower third of the jaws

Q How does this integrate with my existing PLC/SCADA system?
A The crusher comes with a standard control panel featuring Modbus TCP/IP protocol allowing direct communication with most plantwide control systems for data monitoring

Q What is the expected installation timeframe?
A For a skidmounted modular unit site placement connection to power foundations can be completed in 1014 days A traditional stationary installation requires more civil work typically 46 weeks

Q Are wear parts readily available?
A We maintain regional inventory hubs for all critical wear components including jaw plates Offering guaranteed 48hour shipping for emergency orders under our premium service plan

Q Can you provide a detailed analysis of projected ROI?
A Yes Our technical sales team will review your specific ore characteristics current operating costs production goals generate a detailed Total Cost of Ownership TCO comparison against your existing setup