1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are escalating operational costs and unpredictable availability undermining your primary crushing circuit’s profitability? Pour les directeurs d’usine et les entrepreneurs en ingénierie, l'étape de concassage primaire est un goulot d'étranglement critique où les inefficacités se répercutent sur l'ensemble du processus en aval. Common challenges with outdated or underperforming gyratory crushers include:

Temps d'arrêt imprévus excessifs: Pannes mécaniques fréquentes, such as bottom shell bushing wear or mainshaft issues, lead to production halts costing tens of thousands per hour in lost throughput.
Coûts de maintenance élevés & Intensité du travail: Les conceptions traditionnelles nécessitent de longues, complex procedures for wear part inspection and replacement, demanding significant manhours and specialized tooling.
Taille du produit incohérente & Capacité: Les broyeurs usés ou mal réglés produisent une alimentation hors spécifications pour les circuits secondaires, reducing overall plant efficiency and final product yield.
Consommation d’énergie en hausse: Inefficient crushing chambers and outdated drive systems consume excessive power per ton of processed material, directly impacting operating expenses.

Is your operation equipped to handle increasing ore hardness and throughput demands while controlling maintenance budgets? The solution lies in selecting a gyratory crusher backed by robust engineering and a verifiable manufacturer certificate.

2. APERÇU DU PRODUIT: BROYEUR GIRATOIRE PRIMAIRE LOURD

Cet équipement est d'une grande capacité, compressivestyle primary gyratory crusher engineered for the first stage of reducing runofmine ore or quarry rock. Sa fonction principale est d'accepter des matières premières de grande taille (généralement jusqu'à 1,5 m de taille) and reliably deliver a consistent, coarse product for conveyor transport to subsequent processing stages.

Flux de travail opérationnel:
1. Acceptation des aliments: Large dump trucks or loaders deposit material directly into the crusher’s feed hopper.
2. Concassage compressif: The central gyrating mantle eccentrically compresses material against the stationary concave liners, fracturing rock via highpressure compression.
3. Décharge: Crushed material gravitates through the increasingly narrow chamber until it reaches the desired size and exits through the discharge opening at the bottom.

Champ d'application: Idéal pour les tonnages élevés (2,000+ tph) mining of hard rock metals (cuivre, minerai de fer) and largescale aggregate quarry operations. It is the preferred solution for abrasive materials and blocky feeds where high availability is nonnegotiable.

Limites: Ne convient pas aux opérations de faible tonnage (<500 tph) en raison du coût élevé du capital. Nécessite une écurie, reinforced concrete foundation and significant headroom for installation and maintenance. Less effective for processing clayey or highly plastic materials that may cause packing.

3. CARACTÉRISTIQUES PRINCIPALES

Conception d'araignée brevetée | Base technique: Multibras, forged steel construction with top shell bushing integration | Avantage opérationnel: Provides superior load distribution and alignment for the mainshaft, reducing stress concentrations | Impact sur le retour sur investissement: Prolonge les intervalles d'entretien jusqu'à 30%, lowering lifetime structural repair costs.

Régulation de réglage automatique intégrée (RSA) | Base technique: Hydraulic adjustment system with realtime position sensors | Avantage opérationnel: Allows operators to adjust the crusher discharge setting (CSS) under load in under one minute | Impact sur le retour sur investissement: Minimizes downtime for product size changes by over 95% compared to manual shim adjustment.

Concave Segment Locking System | Base technique: Radial mechanical locking bolts accessible from top | Avantage opérationnel: Permet de sécuriser, faster concave liner changes without entering the crushing chamber from below | Impact sur le retour sur investissement: Réduit d’environ le temps d’arrêt pour le remplacement du revêtement 40%, augmentation des heures de fonctionnement annuelles disponibles.

HighPerformance Main Shaft Design | Base technique: Forged from highstrength alloy steel with precisionmachined bearing surfaces | Avantage opérationnel: Withstands extreme cyclical loading with minimal deflection, ensuring consistent cavity geometry | Impact sur le retour sur investissement: Improves bearing life by an average of 15% basé sur des données de terrain, reducing major component replacement frequency.

StateoftheArt Lubrication System | Base technique: Dualcircuit, temperaturecontrolled filtration with failsafe monitoring | Avantage opérationnel: Ensures clean oil delivery to critical bearings under all operating conditions; continuous contamination removal extends oil life | Impact sur le retour sur investissement: Empêche une estimation 70% des défaillances liées aux roulements, avoiding associated unplanned stoppages.

Robust Bottom Shell Bushing Assembly | Base technique: Precisionfitted bronze bushings with optimized lubrication grooves | Avantage opérationnel: Maintains accurate eccentric throw under peak loads for consistent throughput and product gradation | Impact sur le retour sur investissement: Directly contributes to achieving rated capacity targets over longer campaigns, maximizing revenue potential.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Notre solution de concasseur giratoire | Avantage documenté |
| : | : | : | : |
| Disponibilité mécanique (Annuel) | 92 94%| 96 97%| +3% amélioration |
| Temps d'arrêt pour changement de revêtement (Major Set) | 36 48 heures| 24 30 heures| ~35 % plus rapide |
| Consommation d'énergie (kWh/tonne) Varie selon le matériau.| Ligne de base = 100%| 92 95%| 58% plus efficace |
| Temps moyen entre les pannes (MTBF) Critical Assemblies| ~4 500 heures| >6,000 heures| +33% fiabilité |

Note: Advantages are based on internal field performance audits comparing previous generation models against current design under comparable conditions.

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 2,000 à plus 10,000 tonnes métriques par heure (tph), en fonction du choix du modèle et du matériau d'alimentation.
Puissance du moteur: Lecteurs standards de 450 kW jusqu'à 1,200 kW.
Ouverture d'alimentation: Tailles d'ouverture de 1,050 mm (42") à 1,500 mm (60").
Plage de réglage du réglage de décharge: Typically from 130mm to 280mm CSS.
Spécifications des matériaux clés:
Cadre principal & Coque supérieure: Hightensile cast steel.
Manteau & Concave Liners:Alliages d'acier au manganèse (Standard); Optional chromewhite iron or composite alloys for highly abrasive feeds.
Arbre principal:Carbonchromemolybdenum forged steel.
Approximate Installed Weight: Ranges from ~250 tonnes to >600 tonnes depending on size.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 40°C à +50°C. Dust sealing systems are rated for operational altitudes up to 3,000 mètres au-dessus du niveau de la mer.

6. SCÉNARIOS D'APPLICATION

Projet d'agrandissement de la mine de cuivre

Défi:Une opération majeure de cuivre était nécessaire pour augmenter le débit de broyage primaire de 25% without expanding their truck dump pocket footprint or compromising reliability in highly abrasive ore.Solution:The installation of a new series heavyduty gyratory crusher featuring our advanced concave system and highcapacity chamber design.Résultats: Nous avons obtenu une augmentation soutenue du débit de 28%. Liner life improved by an average of18%, contributing directly to meeting expanded production targets within planned maintenance windows.

Modernisation de la carrière de granulats de granit

Défi:A large quarry faced prohibitive downtime during concave liner changes on their aging primary crusher,scheduled every9 months,and struggled with inconsistent product sizing.Solution:Replacement with a modern gyratory crusher equipped with the Integrated Automatic Setting Regulation(RSA)and topservice concave system.Résultats:Liner change time reduced from44 hours to27 hours.Product consistency improved,variation in CSS reduced by70%,leadingto optimized secondary circuit performance.Financial payback was achieved in under22 months through productivity gains.

7.CONSIDÉRATIONS COMMERCIALES

Our heavyduty primary gyratory crushers are capital investments engineeredfor longterm total cost of ownership reduction.Commercial offerings are structured as follows:

Niveaux de tarification:Capital pricing is modeldependent,based on size(bâiller)and selected configuration options.Equipment packages typically include the crusher,moteurs,Courroies trapézoïdales,système de lubrification,et instrumentation de base

.Fonctionnalités facultatives & Mises à niveau:These include advanced condition monitoring sensors( vibration,température),systèmes automatisés de mesure des pièces d'usure,kits d'anneaux de suppression de poussière,and specialized liner metallurgiesfor specific ore types

.Forfaits de services:We offer tiered service agreements covering scheduled inspections,assistance à la maintenance prédictive,and priority accessto technical specialists.Planned maintenance contracts can be structuredto fix annual operating costsfor critical wear components

.Options de financement:Flexible commercial terms are available includingstraight capital purchase,structures de location de flotte,and projectbased financing solutions tailoredto greenfield developmentsor major expansion projects

.8.FAQ

Q:What documentation is includedwiththe manufacturer certificate?
UN:The formal manufacturer certificate attests thatthe equipment was designed,machined,and assembled tomeet all stated specifications.Itis supportedby mill test reportsfor major steel castingsand forgings,dimensional inspection reports,and functional test recordsfor assembled subsystems

.Q:Canyourgyratorycrusherbe integratedintoour existing PLC/plant control system?
A Yes.All units come standardwith modern control interfaces(typically Ethernet/IPor Modbus TCP).Our engineering team can provide necessary communication protocolsand points listsfor seamless integration intoyour wider plant SCADA network

.Q:Quel est le délai de livraison typique entre la commande et la mise en service?
A Lead times varyby model complexityand current production scheduling.For standard configurations,target lead times range between10and14 months.This includes manufacturing,tests en usine,and preparationfor shipment.Detailed schedulesare provided upon project initiation

.Q Howdoesthe automatic setting regulation impactproduct quality?
A The ASR system maintains adiscrete closedloop controlon themantle position.Field data shows this reduces CSS variationby over80%comparedtomanual methodsunder load.This resultsin amore consistentfeed sizefor secondaryand tertiary stages improving overall circuit stabilityand product yield

.Q Whattrainingis providedfor ourmaintenance crew?
A We provide comprehensive onsite training during commissioning covering normal operation routine inspections lockout/tagout proceduresand detailed stepbystep training formajor wear part replacement.Thisis supplementedby detailed service manualsand instructional videos

.Q Arewear parts interchangeablewith other OEMs'crushers?
A No Ourgyratorycrusheris designedwith proprietarygeometryand mounting systems tomaximize performance.Wear partsare notmechanically interchangeablewith thosefrom other manufacturersensuring optimal fit functionand longevityas intendedby ourdesign engineers

.Q Whatisthe expectedservice lifeforthemajor structural components?
A The main frame top shelland bottom shellare designed fora minimumservice lifeof30+yearsunder normal operating conditions when maintained accordingto our prescribed schedules.Thisis basedon finite element analysis(FEA)and historical performance datafrom earliergeneration unitsstill in operation