1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Les coûts opérationnels croissants et la disponibilité imprévisible érodent-ils la rentabilité de votre circuit de concassage principal ?? Key challenges in gyratory crusher operations directly impact your bottom line:
Temps d'arrêt imprévus: Bearing failures or mainshaft issues can halt your entire processing line for days, coûtant des centaines de milliers de dollars en perte de production.
Coûts de maintenance élevés: Fréquent, laborintensive liner changes and component wear consume both maintenance budgets and valuable operating hours.
Débit incohérent & Taille du produit: Les fluctuations des matières premières ou l'usure au fil du temps conduisent à un produit non conforme aux spécifications., creating bottlenecks and reducing downstream efficiency.
Consommation d'énergie excessive: Older or inefficient designs draw more power per ton processed, a fixed cost that significantly impacts operating margins.

Comment obtenir un débit plus élevé avec une plus grande fiabilité tout en contrôlant le coût total de possession? The solution requires a crusher engineered not just for peak performance, mais pour une durée soutenue, predictable operation under the most demanding conditions.

2. APERÇU DU PRODUIT

The Custom Gyratory Crusher is a heavyduty, primary crushing machine designed for hightonnage, continuous operation in largescale mining and aggregate production. It performs compressive crushing via a gyrating mantle within a concave hopper.

Flux de travail opérationnel:
1. Consommation alimentaire: Runofmine (ROM) ore or large quarry rock is directly dumped into the top of the crusher’s deep, nonchoking concave.
2. Concassage compressif: The eccentrically gyrating mantle repeatedly advances and recedes from the concave liners, applying massive compressive force to reduce material size.
3. Contrôle des paramètres de décharge: The crushed product exits through the adjustable bottom setting (ABS), avec une taille déterminée par le réglage du côté fermé (CSS) between the mantle and concave at their lowest point.
4. Décharge & Transport: Sized material is discharged onto a primary conveyor for transport to the next stage of processing.

Champ d'application: Ideal for primary crushing of abrasive hard rock (minerai de fer, minerai de cuivre, granit), hightonnage aggregate production, and heap leach applications requiring coarse product. Not recommended for lowtonnage operations, soft or nonabrasive materials only, or sites with severe space constraints where a jaw crusher may be more appropriate.

3. CARACTÉRISTIQUES PRINCIPALES

Patented QS™ Quill Shaft System | Base technique: Isolated eccentric motion with hydrostatic lubrication | Avantage opérationnel: Eliminates metaltometal contact in the eccentric assembly, drastically reducing wear and risk of catastrophic failure | Impact sur le retour sur investissement: Les données de terrain s'affichent jusqu'à 40% longer service intervals for the eccentric system and a documented 60% réduction des temps d’arrêt imprévus associés.

INTEGRAL™ Concave & Mantle Liner System | Base technique: Interlocking alloy segments with optimized chamber geometry | Avantage opérationnel: Provides more consistent product gradation throughout liner life and reduces changeout time by up to 30% compared to traditional designs | Impact sur le retour sur investissement: Lower liner cost per ton crushed and increased crusher availability for production.

SMARTSENSE™ Bearing Monitoring | Base technique: Integrated vibration, température, and pressure sensors on critical bearings | Avantage opérationnel: Your maintenance team receives realtime health data and predictive alerts, enabling conditionbased maintenance planning | Impact sur le retour sur investissement: Prevents unexpected bearing failures, protects against secondary damage to shafts and housings.

HYDROSET® PLUS Chamber Clearing & Ajustement | Base technique: Dualfunction hydraulic ram system for setting adjustment and automated chamber clearing | Avantage opérationnel: Operators can adjust CSS under load or clear a stalled cavity remotely in minutes from the control room | Impact sur le retour sur investissement: Maximise la disponibilité; eliminates hours of manual clearing efforts and associated safety risks.

HEAVYDUTY Spiral Bevel Gear & Pignon | Base technique: Forged alloy steel gears with computeroptimized tooth profile | Avantage opérationnel: Transmits high torque smoothly with minimal noise and vibration, even under uneven loading conditions | Impact sur le retour sur investissement: Industry testing demonstrates a typical service life extension of 25% over standard gear sets under comparable duty cycles.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Moyenne standard de l’industrie | Custom Gyratory Crusher Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité (Exécution planifiée) | 9294% | 96.5%+ | +35% |
| Temps de changement de doublure (Heures) | 2436 heures | 1620 heures | ~40 % plus rapide |
| Consommation d'énergie (kWh/t) Baseline Ore| 0.8 1.2 kWh/t| 0.65 0.9 kWh/t| Jusqu'à 20% Plus efficace |
| Temps moyen entre les pannes (MTBF) Eccentric System| ~12,000 hrs| >18,000 heures| +50% Fiabilité |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Modèles configurables à partir de 2,000 tph à plus 10,000 tph.
Ouverture d'alimentation: Depuis 1,070 mm (42») jusqu'à 1,520 mm (60») dépend du modèle.
Exigence de puissance du moteur: Typiquement 375 kW à 750 kW (500 HP à 1000 PV+), fourni à 6.6 kV or as required.
Poids total: Ranges from approximately 150 tonnes à plus 400 tonnes pour les plus grandes configurations.
Spécifications des matériaux clés:
Cadre principal & Coque supérieure: Highstrength fabricated steel with stressrelieving treatment.
Mainshaft: Forged from highalloy nickelchromiummolybdenum steel.
Concave & Doublures de manteau: Alliages d'acier au manganèse (14%18% Mn), optional chromewhite iron or composite alloys for specific abrasion/corrosion applications.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 40°C à +50°C. Dust seals rated for harsh environments; systèmes de chauffage/refroidissement en option disponibles.

6. SCÉNARIOS D'APPLICATION

Expansion d’une mine de cuivre à grande échelle

Défi: A planned expansion required a primary crusher capable of handling an additional 8 million tonnes per annum of highly abrasive porphyry ore without increasing footprint or headcount disproportionately.
Solution: Installation of one Custom Gyratory Crusher with INTEGRAL™ liners configured for coarse crushing ahead of SAG mills.
Résultats: A atteint un débit soutenu de 4,500 tph at a consistent P80 of 150mm. La durée de vie du revêtement a augmenté en moyenne de 15%, contributing to a calculated total cost per tonne reduction of approximately $0.12 across the crushing circuit.

Carrière de granit à haute production

Défi: Frequent downtime due to tramp metal events causing damage and lengthy cavity clearing procedures was limiting annual output targets.
Solution: Implementation of our gyratory crusher equipped with the HYDROSET® PLUS system and SMARTSENSE™ monitoring.
Résultats: Cavity clearing events reduced from an average operational delay of 8 heures à moins 45 minutes per incident. Annual plant availability increased by over 300 heures (12+ jours), directly translating to an additional ~450k tonnes crushed per year within existing shifts.

7 CONSIDÉRATIONS COMMERCIALES

Equipment pricing is structured into three primary tiers based on size/capacity (CGC50 Series, CGC60 Series, CGC72 Series) with base configurations including core drive system controls motor starter lubrication unit

Les fonctionnalités optionnelles incluent:
Advanced automation packages remote diagnostic telemetry special alloy liner packages dust suppression ring

Les forfaits de services sont proposés séparément:
Bronze (Garantie de base) Argent (Planned Inspection & Parts Discount) Or (FullService Contract including scheduled labor parts predictive monitoring)

Financing options are available through our partners including capital lease operating lease project financing terms typically structured over years

FAQ

Quel est le calendrier d'installation typique?
From delivery onsite mechanical erection electrical connection commissioning full operation typically requires weeks depending on foundation readiness site support

How does this crusher integrate with my existing control system?
The crushers PLC is designed for interoperability providing standard communication protocols Modbus TCP/IP Profibus We supply full interface documentation

Can you provide wear part cost guarantees?
Yes we offer guaranteed maximum wear part cost per tonne contracts based on your specific feed material analysis providing predictable longterm budgeting

Quelles sont vos conditions de paiement?
Standard commercial terms involve progress payments tied key milestones delivery acceptance Final payment due upon successful completion performance run

Proposez-vous une formation aux opérateurs?
Comprehensive training is included covering safe operation routine maintenance troubleshooting conducted both at commissioning at your facility