1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

La gestion d'un circuit de concassage de minerai de fer présente des, des défis coûteux. Are you experiencing persistent bottlenecks that limit your plant’s rated throughput? Are unscheduled maintenance stops and premature wear part failures eroding your operating budget and creating unpredictable downtime? Is inconsistent product sizing leading to inefficiencies in downstream grinding and processing, ultimately affecting pellet or sinter quality? En outre, does the total cost of ownership for your primary crushing stage—factoring in energy consumption, liner replacements, and labor—exceed initial projections? These operational hurdles directly impact profitability. La question centrale pour les directeurs d'usine est la suivante: comment pouvez-vous obtenir un, hightonnage reduction of abrasive iron ore while controlling operational costs and maximizing plant availability?

2. APERÇU DU PRODUIT

Ce produit est un Concasseur giratoire primaire engineered specifically for highcapacity iron ore processing. It is designed as the first critical stage in a mineral processing plant, receiving runofmine (ROM) feed directly from the pit.

Flux de travail opérationnel:
1. Consommation alimentaire: Minerai de fer ROM (jusqu'à 1,5 m de taille de morceau) is dumped into the crusher’s deep, trémie de réception sans étouffement.
2. Action écrasante: A centrally mounted mantle gyrates within a concave bowl, applying compressive force to break the ore against itself.
3. Décharge: Crushed material exits through the bottom setting (CSS), with product size typically ranging from 150mm to 250mm for feed to secondary crushing or SAG mill circuits.

Champ d'application & Limites:
Portée: Ideal for largescale mining operations with high daily tonnage requirements (>10,000 MTD). Suited for processing hard, abrasive hematite and magnetite ores.
Limites: Not designed for final product sizing or for processing materials with high clay or moisture content without adequate prescreening/scalping. Nécessite une fondation en béton stable et une hauteur libre importante pour l'installation et l'entretien.

3. CARACTÉRISTIQUES PRINCIPALES

Conception concave brevetée | Base technique: Segmenté, reversible alloy steel segments | Avantage opérationnel: Prolonge la durée de vie jusqu'à 30% by allowing rotation and use of multiple wear surfaces before replacement | Impact sur le retour sur investissement: Reduces liner inventory costs and downtime for concave changes

Régulation de réglage automatique intégrée | Base technique: Système de réglage hydraulique avec capteurs de position | Avantage opérationnel: Allows operators to adjust the crusher discharge setting in minutes without stopping the process | Impact sur le retour sur investissement: Maintains optimal product size for downstream efficiency, increasing overall circuit throughput by an estimated 25%

Système de lubrification avec surveillance de l'état | Base technique: Dualcircuit filtration and temperature/pressure sensors feeding to plant DCS | Avantage opérationnel: Provides continuous protection of critical bearings; alerts personnel to potential issues before failure occurs | Impact sur le retour sur investissement: Prevents catastrophic bearing damage, a failure that can result in over 200 heures de production perdues

SpiderMounted Dump Hopper & Seal | Base technique: Reinforced design with multistage dust seal system | Avantage opérationnel: Effectively contains dust at the feed point and prevents contaminant ingress into the main bearing assembly | Impact sur le retour sur investissement: Reduces environmental emissions compliance costs and extends bearing life in dusty conditions

Conception d'arbre principal robuste | Base technique: Forged alloy steel shaft with optimized fatigue resistance profile | Avantage opérationnel: Provides exceptional strength to handle tramp steel and uncrushable material events without shaft deflection or failure | Impact sur le retour sur investissement: Eliminates unplanned outages related to shaft failure, a primary cause of extended downtime in primary crushing

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Moyennes des concurrents) | This Primary Gyratory Crusher Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité (Exécution planifiée) | 9294% | 96%+ documented field average over 24 mois | ~34% d'amélioration |
| Durée de vie du revêtement (Million Tons/Set) Hematite Ore| 4.5 5.5 Mtons | 6.0 7.0 Mtons verified at multiple sites| ~1520% improvement |
| Consommation d'énergie spécifique (kWh/tonne) | 0.18 0.22 kWh/t | 0.15 0.17 kWh/t based on installed motor vs. throughput data| ~18% d'amélioration |
| Tramp Iron PassThrough Recovery Time| Effacement manuel; heures d'arrêt| Hydraulic clearing system; 80% reduction in event duration |

5. SPÉCIFICATIONS TECHNIQUES

Désignation du modèle: PGC60110
Ouverture d'alimentation: 1,520 mm (60 pouces)
Plage de capacité nominale: 3,500 7,500 mtph (dependent on ore characteristics and discharge setting)
Puissance installée: 600 kW (800 HP) electric drive motor
Arbre principal: Forged ES355 alloy steel
Concave & Mantle Material: ASTM A128 Manganese Steel with proprietary heat treatment
Poids total (Concasseur uniquement): ~275 metric tons
Top Shell Diameter: ~4.8 meters
Plage de température de fonctionnement: 30°C à +45°C (with appropriate lube oil specifications)
Contrôle de la poussière: Integral connection points for plant dust extraction system.

6. SCÉNARIOS D'APPLICATION

LargeScale Open Pit Mine – Australia Challenge:

A major hematite operation faced declining feed grades, requiring higher throughput volumes through their primary crushing station to maintain annual production targets. Their existing crusher was unable to achieve higher tonnage without excessive wear and energy costs.

Solution:

Implementation of one PGC60110 Primary Gyratory Crusher with the integrated automatic setting system.

Résultats:

Within six months of commissioning:
Sustained throughput increased by 18%, meeting upgraded plant demands.
Energy cost per ton crushed decreased by 16%.
Annual planned maintenance hours were reduced by 120 hours due to extended liner intervals.

Magnetite Concentrator – North America Challenge:

The client’s new greenfield project required a primary crusher capable of handling extremely hard magnetite ore while guaranteeing >95% availability as the single point of failure for the entire coarse ore circuit.

Solution:

Installation of two PGC60110 crushers configured with full condition monitoring on lube systems and main bearings.

Résultats:

Over the first two years of operation:
Achieved an average operational availability of 96.7%.
Successfully passed multiple tramp metal events without damage via the hydraulic release system.
Condition monitoring provided actionable data that allowed scheduling of a bearing inspection during a planned plant shutdown, avoiding a predicted inservice failure.

7 CONSIDÉRATIONS COMMERCIALES

Our commercial model is structured around providing predictable total cost outcomes.

Niveaux de tarification des équipements: Pricing is based on configuration.
Configuration de base: Core crusher assembly with standard lubrication unit.
Configuration avancée: Includes automatic setting regulation (RSA), capteurs avancés de surveillance de l'état, and upgraded dust sealing.
Turnkey SkidMounted Unit: Crusher preassembled on a structural skid base with walkways, échelles, and integrated lubrication system for faster installation.

Fonctionnalités facultatives & Mises à niveau: Wear monitoring systems via concave wear sensors; premium ceramic composite liners for specific abrasion zones; custom discharge conveyor flanges; extended warranty packages on major castings.

Forfaits de services:
Contrat de maintenance planifiée: Inspections programmées, oil analysis programs, et support technique.
Liner Service Contract: Guaranteed liner life performance with fixedcostperton replacement parts.
Contrat de service complet: Couvre toutes les pièces (porter & mécanique), travail, and field service engineering for a fixed annual fee.

Options de financement: We offer several capital solutions including traditional equipment financing/leasing through our partners or performancebased contracting models where payments can be partially linked to achieved availability or throughput guarantees.

8 FAQ

1.Q What is the lead time from order placement to delivery?
A For standard models like the PGC60110 lead times are typically between 912 months due to extensive forging and machining requirements for major components like the main shaft and top shell castings

2.Q How does this crusher integrate with our existing PLC/SCADA control system?
A The unit comes standard with an AllenBradley ControlLogix PLC local panel All critical operational data pressure temperature motor status ASR position are communicated via industrystandard Modbus TCP/IP or Ethernet/IP protocols allowing straightforward integration into your wider plant control network

3.Q What are your recommendations regarding feed size distribution?
A For optimal performance we recommend ROM feed where no more than XNUMX% exceeds XNUMX times the nominal feed opening size Consistent feeding using a vibrating grizzly feeder or apron feeder is critical Our engineering team can review your specific mine plan geology data

4.Q Do you provide installation supervision?
A Yes we offer optional expert field service supervision during installation commissioning This service ensures correct mechanical alignment electrical connection verification lubrication system flushing procedure adherence which directly impacts longterm reliability

5.Q What are typical spare parts inventory recommendations?
A We provide sitespecific recommendations based on your operating schedule However we maintain regional stockholding centers globally offering XNUMX/XNUMX emergency parts dispatch Critical spares like main shaft step washers eccentric bushings should be held onsite per our recommended list

6.Q Can you guarantee performance metrics like capacity or liner life?
A Formal performance guarantees are provided as part of our commercial proposal following detailed review analysis of your representative ore samples geotechnical data These guarantees form part binding contract subject defined test protocols postcommissioning