1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing escalating maintenance costs and unpredictable downtime in your cement production line? The critical process of material size reduction directly impacts your plant's throughput, energy expenditure, and product quality consistency. Common challenges with outdated or underperforming crushing equipment include:

Consommation d'énergie excessive: Inefficient crushers can account for over 30% of your milling circuit's power draw, érodant directement les marges bénéficiaires.
Temps d'arrêt imprévus: Frequent mechanical failures and lengthy liner changes halt the entire raw material preparation stage, coûtant des milliers de dollars par heure en perte de production.
Taille d'alimentation incohérente: Poorly controlled product size increases the load and wear on downstream ball mills, reducing their efficiency and increasing grinding media consumption.
Coûts élevés de remplacement des pièces d’usure: Rapid degradation of hammers, rotors, and liners due to abrasive silica and alumina in raw mix leads to high spare part inventories and labor costs.

Is your current crushing solution delivering the reliability and costperton needed to remain competitive? The right primary crusher is not just a purchase; it's a strategic investment in plantwide stability.

2. APERÇU DU PRODUIT

The Gyratory Crusher is a primary crushing station engineered for the first stage of size reduction in cement raw material processing. It is designed to handle large feed blocks of quarried limestone, marl, or clay at high throughput rates with continuous operation.

Flux de travail opérationnel:
1. Dump trucks or feeders deliver large (jusqu'à 1,5 m) raw material blocks into the crusher’s deep, rugged feed hopper.
2. L'arbre principal à entraînement excentrique fait tourner le manteau, appliquer une force de compression contre les revêtements concaves stationnaires.
3. Material is crushed by repeated compression cycles as it travels down through the chamber.
4. The crushed product discharges through the adjustable bottom shell setting, determining the final output size for conveyor transport to prehomogenization stockpiles.

Champ d'application & Limites:
Portée: Ideal for highcapacity cement plants (2,500+ DPT) processing hard to mediumhard abrasive raw materials. It is the preferred solution for stationary primary crushing stations requiring continuous, reliable operation with minimal fines generation.
Limites: Requires a substantial capital investment and reinforced concrete foundation. Not suitable for mobile applications or for processing materials with high plasticity or moisture content that could cause packing.

3. CARACTÉRISTIQUES PRINCIPALES

Conception d'araignée brevetée | Base technique: Construction multibras en acier forgé avec joint d'étanchéité de la coque supérieure | Avantage opérationnel: Répartit la charge uniformément, prevents dust ingress, and provides secure mounting for mantle | Impact sur le retour sur investissement: Prolonge les intervalles d'entretien jusqu'à 40%, reducing annual maintenance hours.

HydroSet System | Base technique: Hydraulic piston for main shaft positioning and overload protection | Avantage opérationnel: Allows remote adjustment of crusher discharge setting and automatic clearing of blockages in under 60 secondes | Impact sur le retour sur investissement: Minimizes downtime for product size changes and eliminates manual intervention for tramp iron events.

Concave Liner Profiles | Base technique: Computeroptimized chamber designs (standard, grossier, bien) | Avantage opérationnel: Maximizes throughput capacity and controls product gradation for optimal downstream mill feed | Impact sur le retour sur investissement: Atteint jusqu'à 15% higher throughput per installed horsepower compared to nonoptimized designs.

Integrated Main Shaft Lubrication | Base technique: Dedicated pressurized oil circulation system with temperature monitoring | Avantage opérationnel: Ensures constant lubrication of bearings under extreme load, preventing seizure and catastrophic failure | Impact sur le retour sur investissement: Protects core asset integrity; les données de terrain montrent un >90% réduction des défaillances liées aux roulements.

Automated Wear Monitoring | Base technique: Laserbased concave liner thickness scanning system (facultatif) | Avantage opérationnel: Fournit des informations précises, realtime data on liner wear without requiring entry into the crusher cavity | Impact sur le retour sur investissement: Enables predictive liner scheduling, optimizing changeouts during planned stops and avoiding unexpected failures.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Curseur de mâchoire) | Solution de concasseur giratoire | Avantage (% amélioration) |
| : | : | : | : |
| Disponibilité (%) | 85 90% | 94 96%| +6% (temps d'arrêt réduit) |
| Coût d'exploitation ($/tonne)| $0.50 $0.70| $0.35 $0.45| 30% (lower wear & pouvoir) |
| Efficacité énergétique (kWh/tonne)| 0.8 1.2| 0.6 0.8| 25% (lower power draw) |
| Durée de vie du revêtement (Millions de tonnes)| 0.8 1.2 Mt| 1.5 2.5 Mt| +80% (longer intervals) |
| Taille maximale d'alimentation / Capacity Ratio| Lower ratio limits top size at high capacity| Higher ratio allows larger feed at same capacity| +35% (handles bigger blocks) |

5.SPÉCIFICATIONS TECHNIQUES

Plage de capacité: 2,000 – 10,000 tonnes métriques par heure (dépendant du matériau).
Ouverture d'alimentation: Ranging from 800mm to 1500mm.
Puissance du moteur: 250 kW – 800 kW selon la taille du modèle.
Plage de réglage du réglage de décharge: 100mm – 250mm via HydroSet system.
Main Shell & Doublures: Châssis principal en acier moulé à haute résistance; Manganese steel concave and mantle liners (1418% Mn).
Dimensions physiques / Poids: Environ. hauteur: ~57m; poids: ~120 – 400 tonnes (including base frame).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dusttight construction for indoor or outdoor installation.

6. SCÉNARIOS D'APPLICATION

LargeScale Integrated Cement Plant Expansion

Défi:
A major producer expanding to a new 8,000 TPD line needed a primary crusher capable of processing highly abrasive limestone with minimal fines generation while guaranteeing >95% availability to protect their massive capital investment downstream.
Solution:
Installation of a heavyduty Gyratory Crusher with an optimized coarse crushing chamber profile.
Résultats:
Atteint cohérent <200mm product at a rate of over 2 ,200 tph . Disponibilité des plantes dépassée 96 % la première année , with energy consumption measured at 0 .68 kWh / tonne , directly supporting project ROI targets .

Modernization of Aging Crushing Circuit

Défi:
An existing plant faced spiraling maintenance costs and weekly unplanned stoppages on its old primary jaw crushers , bottlenecking overall kiln feed capacity .
Solution:
Replacement of two parallel jaw crushers with a single , modern Gyratory Crusher , utilizing the existing feed system footprint .
Résultats:
Le débit a augmenté de 25 % while total connected power dropped by 180 kW . Les coûts de maintenance annuels ont diminué d'environ 45 % due to fewer wear parts and longer service cycles , justifying the capital expenditure within 22 mois .

7. CONSIDÉRATIONS COMMERCIALES

Equipment pricing is structured according to capacity rating , configuration du lecteur ,and levelof factoryintegrated automation . We offer three core tiers :

• Niveau I : Base Model – Includes core crusher , standard lubrication system ,et instrumentation de base . Suitablefor clientswith existing comprehensive maintenance teams .
• Niveau II : Performance Model – Adds the HydroSet automation package , enhanced condition monitoring sensors ,and premium alloy liners . Recommendedfor maximum operational efficiency .
• Niveau III : PlantReady Model – Fully integrated package including motor , VFD starter , automated lubrication cooling,and PLC control interface readyfor tiein .

Fonctionnalités facultatives :
• Automated wear monitoring system
• Special alloy liners forextreme abrasion
• Spare parts kits(initial fill)
• Remote diagnostic connectivity

Forfaits de services :
Comprehensive support agreements are available covering scheduled inspections predictive maintenance planning,et fourniture de pièces prioritaires . Financing options including leasetoown structuresand project financing can be tailoredto alignwith your capital planning cycles .

8. FAQ

T1 : Isa gyratory crusher compatiblewith our existing secondary impact crushers ?
A1 : Oui . A gyratory cruser providesa controlled coarse product that isan ideal feedfor secondary crushing stages optimizing overall circuit balanceand reducing wear on downstream equipment .

T2 : Whatisthe typical installation timelineand what site preparationisrequired ?
A2 : From foundation readinessto commissioning requires approximately 14 –18 weeks dependingon model size . Detailed civil engineering drawingsfor thereinforced concrete foundationare provided ;its designis criticalfor longterm stability .

T3 : How doesthe operational cost comparetoa large jawcrusherover five years ?
A3 : Industry data indicatesgyratory crushers typically offer 20–30 % lower total costof ownership over five years primarily due t o superior energy efficiency longerwear part life andreduceddowntime .

T4 : What trainingisprovidedfor our operationsand maintenance staff ?
A4 We provide comprehensive onsite training covering safe operation routine maintenance procedures troubleshooting guidelinesand detailed review ofthe lubricationand hydraulic systems .

Q5 Can this equipment handle stickyor highclay content materials ?
A5 While robust gyratorycrushers perform bestwith dryto moderately moist materials Very high claycontentcan leadto packingin lower sections We recommendmaterial testingand can discuss chamber designoptionsor prescreening solutionsif needed .

Q6 Whatisthe warranty structure?
A6 Our standard warranty covers manufacturing defectsin materialsand workmanshipfor one yearfrom commissioning Extended warranty coverage formajor componentsisavailableaspartofa service agreement .

Q7 How are spare parts logistics managed?
A7 We maintain regional inventory hubsfor criticalwear parts Consignment stock agreementscan be establishedat your site ensuring immediate availabilityof key componentslike mantles concavesand hydraulic parts