1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are escalating maintenance costs and unplanned downtime eroding your primary crushing circuit’s profitability? Plant managers and engineering contractors face persistent operational challenges with their primary crushing stations, including:

Temps d'arrêt excessif pour les changements de revêtement: Les conceptions traditionnelles nécessitent de longues, laborintensive shutdowns for mantle and concave replacement, costing 2448 hours of lost production each cycle.
Gestion incohérente des aliments & SurgeRelated Damage: Pontage, ségrégation, and direct dump surge from haul trucks lead to uneven wear, premature component failure, and cyclical stress on the entire crusher assembly.
Coûts opérationnels élevés & Inefficacité énergétique: Suboptimal crushing chambers and outdated drive systems fail to maximize throughput per kilowatthour, impactant directement votre métrique de coût par personne.
Limited Flexibility for Future Expansion: Fixedcapacity crushers cannot adapt to increased ore hardness or higher tonnage requirements without a complete capitalintensive replacement.

Is your operation equipped to reduce total cost of ownership while improving throughput reliability? The solution lies in specifying a modern, highperformance gyratory crusher from a specialized contract manufacturer.

2. APERÇU DU PRODUIT: BROYEUR GIRATOIRE

A gyratory crusher is a primary compression crushing machine integral to largescale mining and aggregate operations. Il réduit le minerai brut ou les roches extraites en les comprimant entre un revêtement concave fixe et un manteau giratoire monté sur un axe oscillant..

Flux de travail opérationnel:
1. Consommation alimentaire: Material is fed into the top of the crusher via a dump pocket or apron feeder.
2. Concassage par compression: L'ensemble de broche centrale, avec son manteau monté, tourne dans le concave stationnaire. Ce mouvement excentrique comprime à plusieurs reprises la roche contre les parois concaves..
3. Réduction progressive: Rock fragments are crushed progressively as they descend through the chamber until they reach the required discharge size.
4. Décharge: Crushed material exits through the discharge opening at the bottom of the crushing chamber (le réglage côté fermé), conveyed onward for further processing.

Champ d'application & Limites:
Portée: Idéal pour les tonnages élevés (1,500+ tph) primary crushing applications with abrasive or hard ores (par ex., cuivre, minerai de fer, or). Suited for stationary plants with direct dump or large feeder systems.
Limites: Higher capital cost versus jaw crushers; requires substantial foundational support; not suitable for portable plants or lowtonnage operations (<500 tph).

3. CARACTÉRISTIQUES PRINCIPALES

Conception concave brevetée | Base technique: Segmenté, alloyoptimized liners with mechanical locking | Avantage opérationnel: Réduit le temps de changement de doublure jusqu'à 40% versus bolted designs | Impact sur le retour sur investissement: Lowers labor costs and increases plant availability by hundreds of production hours annually.

Intelligent Chamber Profiling | Base technique: CADoptimized chamber geometry based on feed material modeling | Avantage opérationnel: Ensures consistent nipangle and even wear distribution for stable product gradation | Impact sur le retour sur investissement: Prolonge la durée de vie du revêtement de 1525%, reducing consumable cost per ton.

Integrated Main Shaft Position System | Base technique: Realtime hydraulic monitoring of main shaft vertical position | Avantage opérationnel: Allows operators to adjust the closedside setting under load for precise product control | Impact sur le retour sur investissement: Maintains target product size without stopping, optimizing downstream process efficiency.

Hybrid Lubrication & Dust Seal System | Base technique: Multistage labyrinth seals with positivepressure grease barrier | Avantage opérationnel: Effectively excludes abrasive dust from bearing and lubrication systems | Impact sur le retour sur investissement: Empêche la défaillance prématurée des roulements, extending major service intervals by thousands of operating hours.

Entraînement direct & Torque Limiting | Base technique: Lowspeed synchronous motor coupled with an inline torque limiter | Avantage opérationnel: Eliminates Vbelt maintenance and provides controlled slip protection against tramp metal | Impact sur le retour sur investissement: Reduces drive system maintenance costs and prevents catastrophic overload damage.

Advanced Control System Interface | Base technique: PLCbased system with standard MODBUS/OPC protocols | Avantage opérationnel: Enables seamless integration into plantwide SCADA for remote monitoring of power draw, pression, et la température | Impact sur le retour sur investissement: Facilitates predictive maintenance scheduling and optimizes crusher performance in realtime.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Notre solution de concasseur giratoire | Avantage (% amélioration) |
| : | : | : | : |
| Temps de changement de doublure (Majeur) | 3648 heures | 2230 heures | ~40% de réduction |
| Disponibilité (Annuel) | 9294% | 9597%+ | ~35% increase |
| Efficacité de concassage (kWh/tonne) Varie selon le matériau. Baseline established per project. Les données de terrain montrent des réductions de 510% are achievable through optimized chamber design and drive efficiency. |
| Temps moyen entre les pannes (Roulements) ~36,000 hours ~50,000 hours ~39% increase |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 1,500 à plus 12,000 tonnes métriques par heure (tph), en fonction du modèle et du matériau d'alimentation.
Exigences d'alimentation: Entraîner les moteurs de 450 kW jusqu'à 1,200 kW. Electrical supply must be specified per regional standards (par ex., 60Hz/4160V).
Spécifications matérielles: Châssis principal en acier fabriqué à haute résistance; arbre principal en acier allié forgé; manganese or chrome alloy concaves/mantles tailored to abrasion index.
Dimensions physiques (Exemple de modèle): Total height ~68m; installed weight between 250 450 metric tons excluding feed hopper.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 40°C à +50°C. Dust suppression and heating systems available as options.

6. SCÉNARIOS D'APPLICATION

Projet d'agrandissement de la mine de cuivre

Challenge A Tier1 copper miner needed to increase primary circuit throughput by 20% without expanding their footprint or overhauling existing feed conveyors.
Solution Installation of a new highcapacity gyratory crusher featuring an intelligent chamber profile designed specifically for their ore’s abrasiveness and work index.
Results Achieved a sustained throughput increase of 22%. The optimized wear profile extended concave service life by 18%, contributing to a project payback period of under three years based on increased production alone.

Modernisation de l'usine de traitement du minerai de fer

Challenge Chronic downtime due to dust ingress causing bearing failures every 2430 months in a harsh desert environment.
Solution Retrofitted an existing gyratory crusher with our proprietary hybrid lubrication and multistage dust seal system during a scheduled reline.
Results Bearing inspection after 36 months showed no measurable contamination. The plant forecasts extending major bearing service intervals beyond 60 mois, eliminating one full rebuild cycle per decade.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Capital pricing is projectspecific based on size (4265», etc.), spécifications matérielles, et complexité du système de contrôle. Budgetary quotes are provided following a review of feed material characteristics and capacity requirements.
Fonctionnalités facultatives: Key options include automated lubrication systems specific grades alloy liners advanced condition monitoring sensors (vibration temperature) custom discharge conveyor configurations spare parts kits
Forfaits de services: Choose from Foundation Supervision & Installation Commissioning Support MultiYear Maintenance Agreements Remote Diagnostic Support OnSite Training Programs
Options de financement: We partner with leading industrial finance providers to offer competitive leasing structures milestonebased project financing solutions that align payments with your project’s cash flow timeline

8. FAQ

Q1 Are your gyratory crushers compatible with existing foundations from other OEMs?
A While dimensional standardization is limited we conduct full foundation analysis for retrofit projects Custom adapter rings or foundation modifications are engineered as part of the scope to ensure structural integrity

Q2 What is the typical lead time from order placement to commissioning?
A Lead times vary by size complexity For standard models in our portfolio expect manufacturing delivery within months Larger fully custom units may require months Detailed schedules are provided with formal proposals

Q3 How does implementing this equipment impact my ongoing operational staffing?
A Our designs prioritize serviceability reducing specialized labor requirements Field data indicates our liner systems can be handled by existing maintenance crews often without need for additional heavy lifting equipment onsite

Q4 Quelles sont les conditions commerciales standard?
A Standard terms include progress payments tied to manufacturing milestones FOB our facility A performance bond can be provided Final retention payment is typically due upon successful completion of site acceptance tests

Q5 Can you provide wear parts after the initial sale?
A Yes We operate a dedicated parts division offering genuine wear parts concaves mantles etc Competitive lifecycle support packages are available to guarantee part availability optimize longterm operating costs