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 ?? Plant managers and engineering contractors consistently face critical challenges with their primary gyratory crushers, including:

Temps d'arrêt excessif pour la maintenance: Les conceptions traditionnelles nécessitent de longues, complex procedures for wear part replacement and chamber clearing, leading to production losses that can exceed 100 heures par an.
Arrêts imprévus de Tramp Iron: Noncrushable material entering the chamber can cause significant damage, resulting in catastrophic component failure, emergency shutdowns, and sixfigure repair bills.
Débit incohérent & Taille du produit: Worn or poorly configured crushers fail to maintain target product gradation, causing bottlenecks in downstream processes and reducing overall plant efficiency by 515%.
Haut opérationnel & Coûts énergétiques: Inefficient crushing chambers and highfriction components lead to specific energy consumption (kWh/tonne) figures that directly impact your bottom line.

Votre concasseur primaire actuel est-il un actif fiable ou une source récurrente de coûts et de retards? The solution lies in selecting a gyratory crusher engineered not just for capacity, but for total operational cost control.

2. APERÇU DU PRODUIT: BROYEUR GIRATOIRE

Un concasseur giratoire est une machine de concassage par compression stationnaire, essentielle aux opérations minières et d'agrégats à fort tonnage.. It is designed for primary crushing of runofmine ore or blasted quarry rock into a size suitable for secondary processing.

Flux de travail opérationnel:
1. Consommation alimentaire: Matière première de grande taille (jusqu'à 1,5 m de taille) is delivered via haul trucks or loaders into the topmounted feed hopper.
2. Concassage compressif: The central mantle gyrates within the concave liners, applying progressive compressive force to reduce material by pinching and bending.
3. Décharge: Le produit broyé sort par l'ouverture de décharge au fond de la chambre de concassage, its size determined by the closedside setting (CSS).

Champ d'application & Limites:
Portée: Idéal pour les grandes capacités (1,000 10,000+ tph) applications de concassage primaires dans l'exploitation minière de roches dures (minerai de fer, cuivre, or), carrières de granulats à grande échelle, et traitement industriel des minéraux.
Limites: Not suitable for abrasive recycling materials with high metal content. Nécessite une fondation en béton stable et un espace vertical important pour l'installation. Lower initial mobility compared to mobile jaw crusher setups.

3. CARACTÉRISTIQUES PRINCIPALES

Concave breveté & Profils du manteau | Base technique: Computeroptimized chamber geometry based on DEM (Modélisation d'éléments discrets) | Avantage opérationnel: Delivers consistent product gradation throughout the liner life with reduced risk of bridging | Impact sur le retour sur investissement: Maintains downstream circuit efficiency, improving overall plant yield by an estimated 38%.

Système de libération automatique des tramps intégré | Base technique: Hydraulic cylinders support the mainshaft; pressure sensors detect uncrushable material | Avantage opérationnel: Automatically lowers the mainshaft to pass tramp iron, then resumes position without stopping | Impact sur le retour sur investissement: Prevents damageinduced downtime; field data shows a reduction of over 90% in tramp ironrelated stoppages.

Conception de services supérieurs (TSD) | Base technique: All major service components accessible from above via a central service platform | Avantage opérationnel: Enires concaves and mantles can be replaced in 4872 heures contre 710 days with traditional designs | Impact sur le retour sur investissement: Reduces planned maintenance downtime by approximately 70%, translating to thousands of additional production hours over the crusher's life.

HighStrength Alloy Steel Mainframe & Excentrique | Base technique: Forged from highintegrity alloy steel with finite element analysis (FEA) validation | Avantage opérationnel: Provides exceptional durability under extreme cyclical loading with minimal deformation | Impact sur le retour sur investissement: Prolonge la durée de vie structurelle au-delà 30 années, protéger votre investissement en capital à long terme.

Entraînement direct & Variable Speed Capability | Base technique: Lowspeed synchronous motor connected directly to the eccentric via a coupling | Avantage opérationnel: Élimine l'entretien de la courroie trapézoïdale; variable speed allows optimization of throughput and product shape for different feed materials | Impact sur le retour sur investissement: Increases energy transmission efficiency by up to 5% versus traditional drives and provides operational flexibility.

Système de lubrification automatisé centralisé | Base technique: Programmable system delivering precise oil volume and pressure to all critical bearings | Avantage opérationnel: Garantit une température et une santé optimales des roulements, providing early warning diagnostics | Impact sur le retour sur investissement: Extends bearing lifecycles by up to 40% and prevents costly bearing failures.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Notre solution de concasseur giratoire | Avantage documenté |
| : | : | : | : |
| Disponibilité (Annuel) | 92 94% | 96%+| >2% amélioration |
| Consommation d'énergie spécifique| Varie selon le minerai; ligne de base = 100%| 9095% de la ligne de base| 510% reduction in kWh/tonne |
| Temps de changement de doublure (Ensemble complet) | 7 10 jours| 2 3 jours| ~70 % plus rapide |
| Temps moyen entre les pannes (MTBF) Composants majeurs| Industry average established| +35% longer MTBF| Significant reduction in unplanned events |
| Cohérence du débit (Liner Life Variance)| +/15% from newtoworn| +/8% from newtoworn| More stable feed for downstream processes |

5. SPÉCIFICATIONS TECHNIQUES

Gamme de modèles & Capacité: Available in multiple sizes with rated capacities from 1,200 à plus 12,000 tonnes par heure, based on standard crushable ore density.
Exigences d'alimentation: Valeurs nominales du moteur d'entraînement à partir de 300 kW jusqu'à 1,200 kW, dependent on model and application. Electrical supply must match motor specifications.
Spécifications matérielles: Mainframe constructed from hightensile carbon steel plate. Concave and mantle liners available in premium manganese steel alloys or optional composite materials for specific abrasion/impact conditions.
Dimensions physiques & Poids: Feed opening diameters range from 800mm to 1,500mm. Total installed height ranges from 6m to 10m. Machine weights range from 150 à plus 450 tonnes.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 40°C à +50°C. Dust seals are rated for severe environments. Can be equipped with housing heaters or cooling systems as required.

6. SCÉNARIOS D'APPLICATION

Expansion d’une mine de cuivre à grande échelle

Défi: Une exploitation majeure de cuivre nécessaire pour augmenter le débit de l'usine de 25%. The existing primary gyratory was a bottleneck with frequent liner changeover delays exceeding one week.
Solution: Implementation of a new highcapacity gyratory crusher featuring TopService Design and optimized chamber profiles.
Résultats: A atteint un débit soutenu de 8,500 tph. Liner changeouts were completed in under three days each cycle. The project met its expansion CAPEX goals with an estimated payback period of under three years based on increased production.

Modernisation de la carrière de granulats de granit

Défi: An aging primary crusher led to unpredictable product gradation causing inefficiencies in secondary/tertiary stages and high energy costs per ton.
Solution: Replacement with a modern gyratory crusher equipped with variable speed drive and automated control system interfacing with the plant SCADA.
Résultats: Cohérence du produit améliorée, reducing recirculating load in downstream cones by an average of 18%. Overall plant energy consumption per ton of saleable aggregate decreased by 9%.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification des équipements:
Configuration de base (Service standard): Includes core crusher assembly drive motor lubrication system basic instrumentation
Premium Configuration Heavy Duty): Includes upgraded liners enhanced automation package advanced condition monitoring sensors extended warranty
Turnkey SkidMounted Solutions Available

Fonctionnalités facultatives:
Advanced predictive maintenance software integration
Special alloy liner packages for highly abrasive ores
Remote diagnostic capability
Automated setting adjustment system

Forfaits de services:
1 Bronze Plan): Includes scheduled inspections parts discount
2 Silver Plan): Adds annual preventative maintenance labor coverage
3 Gold Plan): Comprehensive coverage including planned liner changeouts guaranteed response times

Options de financement:
Flexible commercial structures are available including capital purchase finance lease or longterm performancebased crushing contracts tailored project financing

FAQ

What are the foundation requirements?
A reinforced concrete foundation designed per supplied load drawings is required typically involving several hundred cubic meters concrete Installation must be performed certified contractors

How does this integrate with our existing SAG mill feed conveyor system?
Our engineering team will provide detailed interface drawings belt loading data Our control systems are designed communicate using standard industrial protocols Modbus TCP/IP Profinet

Quelle est la durée de vie opérationnelle prévue?
The mainframe shell eccentric assembly are designed minimum year lifespan Wear components concaves mantles have service life dependent application typically ranging months several years

Do you offer liner profiling services optimize our specific ore type?
Yes we provide proprietary wear analysis modeling recommend optimal chamber profiles maximize throughput product shape minimize cost per ton crushed This included premium service packages

What are payment terms typical delivery lead time?
Standard terms progress payment milestone Final payment prior shipment Lead times vary model complexity Typically range months order confirmation ex works Expedited options may available