1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing the high costs and operational disruptions inherent in primary crushing? Taille d'alimentation incohérente, minerais abrasifs, and unplanned maintenance create significant bottlenecks. Considérez ces défis communs:
Temps d'arrêt excessif: Unplanned liner changes and mechanical failures halt your entire processing line, coûtant des milliers de dollars par heure en perte de production.
Sortie imprévisible: Fluctuations in gradation and capacity disrupt downstream milling and separation efficiency, compromising final product quality.
Spiraling Operating Costs: Usure prématurée des concaves et des manteaux, couplé à une consommation d’énergie élevée par tonne, érode vos marges bénéficiaires.
Sécurité & Intensité du travail: Traditional adjustment and maintenance procedures increase risk exposure and require skilled personnel for manual interventions.

Votre concasseur primaire actuel est-il un actif fiable ou une source récurrente de coûts et de retards? Un robuste, wellengineered CE Marked Gyratory Crusher is not merely a purchase; it's a strategic investment in plant stability and throughput.

2. APERÇU DU PRODUIT

UN CE Marked Gyratory Crusher est un poids lourd, continuousduty primary crushing machine designed for the first stage of size reduction in largescale mining and aggregate operations. Its core mechanism involves a gyrating mantle within a concave hopper, applying compressive force to break large feed material (dépassant souvent 1 mètre) down to a manageable product for secondary crushing.

Flux de travail opérationnel:
1. Consommation alimentaire: Runofmine (ROM) ore or large quarry rock is directed into the top of the crusher’s deep, concave robuste.
2. Concassage compressif: The eccentrically gyrating mantle repeatedly approaches and recedes from the concave walls, applying progressive compression to fracture the material.
3. Décharge: Crushed product gravitates through the narrowing gap at the bottom (le réglage côté fermé) and exits the crushing chamber for further processing.

Champ d'application: Idéal pour les tonnages élevés (1,500+ tph) applications with hard, matériaux abrasifs comme le granit, minerai de fer, minerai de cuivre, and gold ore. Best suited for fixedplant installations.

Principales limites: Not designed for portable plants or recycling applications with high volumes of tramp metal. Requires a substantial capital investment and engineered foundation.

3. CARACTÉRISTIQUES PRINCIPALES

Patented QS™ Quattro Movement | Base technique: Optimized eccentric throw & stroke combination | Avantage opérationnel: Generates a more aggressive crushing action at the top of the chamber for increased capacity while maintaining controlled discharge grading. | Impact sur le retour sur investissement: Les données de terrain s'affichent jusqu'à 10% higher throughput compared to conventional gyratory designs with identical feed openings.

Système de rétention de doublure (LRS) | Base technique: Mechanically locks concave segments without use of backing material (par ex., epoxy or zinc). | Avantage opérationnel: Réduit le temps de changement de doublure jusqu'à 50% and eliminates hazardous chemical handling. Your maintenance crew can execute safer, faster replacements. | Impact sur le retour sur investissement: Direct labor cost savings and increased crusher availability contribute significantly to lower cost per ton.

Integrated Smart Station (ISS) | Base technique: Centralized PLCbased control hub monitoring mainshaft position, lubrication pressure/temperature, consommation d'énergie, and bearing condition. | Avantage opérationnel: Provides realtime operational data and diagnostics to your plant managers, enabling predictive maintenance and preventing catastrophic failures. | Impact sur le retour sur investissement: Minimise les arrêts imprévus; industry case studies correlate ISS use with a 30% reduction in major mechanical downtime events.

Libération de clochards Hydroset® & Ajustement des paramètres | Base technique: Hydraulic cylinder supports the mainshaft for instantaneous clearing of uncrushable material and remote adjustment of the closedside setting (CSS). | Avantage opérationnel: Operators can clear a stalled chamber or finetune product size from the control room in minutes without entering the crusher bay. | Impact sur le retour sur investissement: Eliminates manual jacking operations, enhancing safety and maximizing productive uptime between shifts.

Spirally Grooved Mainshaft Bearing | Base technique: Precisionengineered grooves ensure optimal oil film distribution across the entire bearing surface under extreme load. | Avantage opérationnel: Extends bearing service life under continuous heavy load cycles by reducing metaltometal contact points that cause wear. | Impact sur le retour sur investissement: Defers major capital overhauls; documented instances show bearing life extensions of 1520% in comparable duty cycles.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | CE Marked Gyratory Crusher Solution | Avantage documenté |
| : | : | : | : |
| Disponibilité (%) | 92 94% moyenne annuelle | >96% annual average achievable| +24% amélioration |
| Temps de changement de doublure (Heures) | 36 48 hours for full concave/mantle set| <24 hours with LRS system| ~50% de réduction |
| Consommation d'énergie (kWh/t) Varie selon le matériau.| Ligne de base = 100%| Réduction moyenne de 57% via une cinématique optimisée| ~57% d'amélioration |
| Temps moyen entre les pannes (MTBF) Composants majeurs| Standard interval based on OEM schedule.| Jusqu'à 20% longer intervals via enhanced bearing & monitoring systems.| +20% extension |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Modeldependent from ~1,500 to over 10,000 tonnes métriques par heure.
Ouverture d'alimentation: Ranges from 600mm x 1400mm up to 1800mm x 4500mm.
Puissance du moteur: Généralement entre 300 kW et 1,000+ kW selon la taille du modèle.
Poids total: À partir d'environ 150 tonnes à plus 500 tonnes for largest models.
Spécifications des matériaux clés: Châssis principal en acier moulé à haute résistance; Acier au manganèse austénitique (MSA) or patented alloy concaves/mantles; forged alloy steel mainshaft.
Plage de température de fonctionnement: Lubrication system engineered for stable operation from 20°C to +50°C ambient conditions.
Conformité & Attestation: CE Marking confirms conformity with EU safety health & environmental protection directives (Machinery Directive).

6. SCÉNARIOS D'APPLICATION

Copper Mine Expansion – Throughput Constraint

Défi: Une exploitation majeure de cuivre nécessaire pour augmenter le débit de l'usine de 25% but was constrained by their existing primary crushing circuit’s peak capacity.
Solution: Installation of a new largecapacity CE Marked Gyratory Crusher with an optimized stroke profile.
Résultats: A atteint un débit soutenu à la capacité nominale de +28%. Consistent product gradation improved SAG mill feed stability.

Granite Aggregate Quarry – Operating Cost Reduction

Défi: High liner wear costs and extensive downtime for manual CSS adjustments were making primary crushing economically inefficient.
Solution: Retrofitted an existing gyratory crusher with modern liners featuring an LRS system paired with an automated Hydroset system.
Résultats: Temps de changement de liner réduit de 40 à 18 heures par événement. Remote CSS adjustments saved an estimated 120 labor hours annually while optimizing yield for premium products.

Iron Ore Processing – Reliability Focus

Défi: Unpredictable bearing failures in a harsh environment caused catastrophic downtime events averaging over one week per incident.
Solution: Procurement of a new CE Marked Gyratory Crusher featuring an advanced spirally grooved mainshaft bearing design coupled with Integrated Smart Station monitoring.
Résultats: Predictive alerts from ISS allowed planned interventions during scheduled stops. Bearing service life increased by an average of three months between planned services over previous models used onsite.

CONSIDÉRATIONS COMMERCIALES

Le prix des équipements est échelonné en fonction de la taille/capacité:
Niveau I (6k tph): Customengineered solutions for megaprojects

Fonctionnalités facultatives:
Système automatisé de surveillance de l'usure
Ensemble d'étanchéité anti-poussière
Extended Wear Component Kits

Forfaits de services:
1.Couverture de garantie de base
2.Planned Maintenance Agreement – includes scheduled inspections & réductions sur les pièces
3.FullService Contract – covers parts & labor under fixed annual cost

Financing Options are available through partner institutions including equipment leasing structures tailored to project cash flow profiles or traditional term loans secured against machinery assets

FAQ

Q1 What does 'CE Marking' specifically guarantee about this gyratory crusher?
A1 CE Marking confirms compliance with mandatory European Union directives related primarily to machinery safety (2006/42/CE). It assures that essential health,sécurité,and environmental protection requirements have been met during manufacture including risk assessment documentation available upon request

Q2 How does this equipment integrate into our existing PLC/SCADA control system?
A2 The crushers are equipped standard industrial communication protocols such as Profibus Modbus TCP/IP Ethernet/IP allowing direct integration into most modern plantwide control systems via its onboard Integrated Smart Station interface module

Q3 What typical lead times apply from order placement commissioning?
A3 Lead times vary significantly based model complexity current manufacturing load Standard Tier II models generally have lead time between months months Large Tier III custom units may require months engineering fabrication delivery Project planning should account these timelines accordingly

Q4 Are performance guarantees offered regarding throughput liner life?
A4 Yes performance guarantees regarding rated capacity power consumption are standard commercial terms Guarantees specific wear rates consumables like liners are typically offered as separate negotiated agreements based agreed reference operating conditions feed material characteristics

Q5 What level foundation preparation required installation?
A5 Detailed geotechnical foundation drawings specifications are provided part technical documentation package Foundations typically require significant mass reinforced concrete designed absorb dynamic loads transmit them substrate Professional civil engineering review sitespecific conditions mandatory prior installation