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 ?? Pour les directeurs d’usine et les entrepreneurs en ingénierie, the primary crushing stage is a critical bottleneck where inefficiencies cascade downstream, directly impacting tonnage and bottom line. Common challenges with outdated or undersized gyratory crushers include:
Temps d'arrêt excessif pour la maintenance: Traditional spider bushing or mantle changes can require 2448 heures de production perdues, costing thousands per hour in idle processing capacity.
Arrêts imprévus de Tramp Iron: Inadequate protection mechanisms lead to costly damage to head nuts, mainshafts, and bushings, resulting in sixfigure repair bills and extended outages.
Débit incohérent & Taille du produit: Worn or poorly designed crushing chambers fail to maintain target discharge settings, causing fluctuations in feed to downstream SAG mills or secondary crushers, réduisant l’efficacité globale de l’usine en 515%.
Consommation d'énergie élevée par tonne: Inefficient crushing action and high friction points force drives to work harder, increasing power costs—often the single largest operating expense.

Is your operation equipped to handle harder ores and higher tonnage demands while controlling maintenance costs and maximizing uptime?

2. APERÇU DU PRODUIT: BROYEUR GIRATOIRE

A gyratory crusher is a cornerstone of highcapacity primary crushing stations in mining and largescale aggregate operations. Il utilise une coque conique fixe (concave) and a gyrating mantle mounted on an eccentric shaft to compress and fragment large feed material (jusqu'à 1,5 m de taille) against itself.

Flux de travail opérationnel:
1. Alimentation: Runofmine (ROM) ore or large quarry rock is directed into the top of the crusher via dump trucks, chargeurs, ou une trémie d'alimentation.
2. Action écrasante: The central shaft gyrates within the concave, creating a progressive crushing cavity that reduces material size with each cycle.
3. Décharge: Le matériau broyé sort par le bas du concasseur (réglage du côté ouvert) onto a conveyor belt for transport to the next stage of processing.

Champ d'application: Ideal for very high throughput applications (2,000 10,000+ tph), processing hard abrasive ores (fer, cuivre, or) and massive aggregate rock. It is the preferred solution for stationary inpit or underground primary crushing installations.

Limites: Requires a substantial capital investment and reinforced concrete foundation. Ne convient pas aux opérations de faible tonnage (<1000 tph), highly plastic or clayrich materials, or portable plant applications where mobility is required.

3. CARACTÉRISTIQUES PRINCIPALES

Conception d'araignée brevetée | Base technique: TopServiceable architecture with rim liners | Avantage opérationnel: Enables all maintenance—including spider arm liners, scellés, and bushings—to be performed from above without dismantling the hydraulic cylinder or bottom shell. | Impact sur le retour sur investissement: Reduces scheduled maintenance downtime by up to 40%, augmentation des heures de production annuelles disponibles.

Système intégré de soulagement des fers clochards | Base technique: Hydraulic support cylinder with automated pressure sensing & release | Avantage opérationnel: Automatically discharges uncrushable material by lowering the mainshaft assembly, preventing damage to critical internal components. | Impact sur le retour sur investissement: Eliminates catastrophic failures from tramp metal; field data shows a reduction in related unplanned downtime by over 90%.

Constant Liner Performance (CLP) Conception de la chambre | Base technique: Computeroptimized concave and mantle profiles | Avantage opérationnel: Maintains a consistent feed opening and product gradation throughout the liner’s life cycle without manual adjustment. | Impact sur le retour sur investissement: Delivers more stable throughput to downstream circuits; les tests de l'industrie démontrent un 7% increase in average tons processed between liner changes.

HighPressure Lubrication System | Base technique: Dualcircuit filtration with temperature monitoring | Avantage opérationnel: Ensures positive oil flow to all critical bearings and gears under peak load conditions, minimizing frictioninduced wear. | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements; documented cases show intervals exceeding 50,000 heures, réduire les coûts d'inventaire des pièces de rechange.

Configuration à entraînement direct | Base technique: Lowspeed synchronous motor coupled directly to the eccentric via a fluid coupling or clutch | Avantage opérationnel: Eliminates Vbelt drives and associated alignment issues; provides full torque at startup under load with higher transmission efficiency. | Impact sur le retour sur investissement: Améliore l’efficacité énergétique d’environ 35% par rapport aux entraînements indirects traditionnels.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Notre solution de concasseur giratoire | Avantage (% amélioration) |
| : | : | : | : |
| Disponibilité (Entretien programmé) | ~92% 94% | >96% moyenne de la flotte documentée| +3% (+250+ operational hours/year) |
| Consommation d'énergie (kWh/tonne) | Varie selon le minerai; ligne de base = 100%| Chambre optimisée & entraînement direct, réduction de la consommation| 4% typical reduction |
| Temps de changement de doublure (Spider/Mantle) | 36 48 heures| Topservice design streamlines process| Downtime reduced by ~35% |
| Temps moyen entre les pannes (MTBF) Roulements| ~30,000 40,000 heures| Advanced lubrication & sealing extends life| >25% augmenter |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 2,000 à plus 12,000 tonnes métriques par heure (tph), selon le modèle et le matériau d'alimentation.
Puissance du moteur: Gamme standard de 450 kW jusqu'à 1,200 kW (600 1,600 HP).
Ouverture d'alimentation: Tailles d'ouverture de 1,070 mm (42») à 1,520 mm (60»).
Cadre principal & Concaves: Fabricated from highstrength steel; concaves available in alloy steel or composite metal matrix materials for specific abrasion/impact conditions.
Dimensions & Poids: Approximate installed height ranges from 6m to 9m; total operating weight between 250 550 tonnes métriques.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 40°C à +50°C avec des systèmes de lubrification appropriés; joints anti-poussière conçus pour les environnements particulaires difficiles.

6. SCÉNARIOS D'APPLICATION

Expansion d’une mine de cuivre à grande échelle

Défi: A tier1 copper operation needed to increase primary crushed throughput by 25% without expanding their existing crusher footprint or foundation. Their legacy equipment could not achieve higher capacity without risking reliability.
Solution: Implementation of a new highcapacity gyratory crusher featuring an optimized CLP chamber design and direct drive system.
Résultats: Achieved targeted throughput increase of 26% within the same footprint while reducing specific energy consumption by 3%. Plant availability improved due to reduced mechanical complexity.

Amélioration de la carrière de granulats de granit

Défi: Unplanned downtime from tramp steel (dents de godet, forets) was causing frequent damage and over $200k annually in repair costs and lost production at a major quarry.
Solution: Retrofit of an existing primary gyratory station with an integrated hydraulic tramp iron relief system and updated control logic.
Résultats: Virtually eliminated major damage events from tramp iron within one year. The system successfully discharged uncrushables on twelve occasions without incident, protecting core components.

7. CONSIDÉRATIONS COMMERCIALES

Gyratory crushers represent a significant capital investment tailored precisely to project requirements.

Niveaux de tarification: Capital cost is primarily determined by size/capacity (par ex., 8ktph models), drive type choice standard vs hightorque),and material specifications standard vs heavyduty alloys).
Fonctionnalités facultatives: Key upgrades include advanced condition monitoring sensors predictive maintenance), automated setting adjustment systems remote CSS control),and special wear packages for highly abrasive ores).
Forfaits de services: Comprehensive plans are available covering scheduled inspections parts kits,and expert field service).These range from basic technical support up through fullperformance guaranteed contracts ensuring uptime targets are met).
Options de financement: To support cash flow management flexible financing structures including leasing longterm rental,and projectbased financing can be arranged aligning payment schedules with operational revenue).

8.FAQ

Q What factors determine whether I need agyratorycrusher versus alarge jawcrusher?
A The decision typically hinges on required throughput total costofownership analysis,and feed material characteristics.Gyratories are generally favored for capacities above1200tph continuous operation on hard abrasive materials where their lower installed height relativetofeedsize provides an advantage.Jawcrushers may be preferredfor lowercapacity applications lessabrasive rockor where modularityis key).

Q How doesyourgyratorycrusherhandle wet sticky ore which can cause packing?
A Specific chamber designs combinedwith enhanced discharge arrangements help mitigate packing.The useof nonchoking concaves alongwith controlled feed distribution reduces this risk.For severe conditions we recommend sitespecific testingto determine optimal configuration).

Q Whatisthe typical lead timefor anewgyratorycrusher?
A For standard models lead timesrange from10to14monthsfrom orderto delivery factoring engineering procurement manufacturing assembly testing.This underscores importanceof early engagement during project feasibility studies).

Q Can yourmoderngyratorycrusherbe integratedintoour existingplant automation system Level2/3)?
A Yes ourcrush erscome standardwith modern PLCcontrol systems that provide open communication protocols OPC UA Modbus TCP/IP enabling seamless integration into widerplant SCADAand process control networksfor centralized monitoringand optimization).

Q Are there financing options availablethat includemaintenance services?
A Yes we offer bundled solutions that combine equipment financingwith comprehensive service agreements.This createsa predictable operational expenditure model covering both capital amortizationand routine maintenance parts protecting against budget overruns).