1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Les coûts opérationnels croissants et la disponibilité imprévisible érodent-ils la rentabilité de votre circuit de concassage primaire? Plant managers and engineering contractors consistently face critical challenges with their primary gyratory crushers: excessive liner wear leading to high consumable costs, unscheduled downtime for mantle changes that halts the entire process flow, and inconsistent feed opening performance causing bottlenecks in downstream operations. En outre, the high energy consumption of an inefficient crusher directly impacts your bottom line, while the complexity of maintenance requires specialized labor and extends repair windows. How do you increase throughput while controlling maintenance costs? Can you achieve greater reliability without compromising on feed size or reduction ratio? The solution requires equipment engineered not just for performance, but for total operational cost management.

2. APERÇU DU PRODUIT

Le [Nom du fabricant] Primary Gyratory Crusher is a heavyduty compression crusher engineered for the first stage of size reduction in hightonnage mining and aggregate operations. Its core function is to accept runofmine or quarry feed material and reduce it to a conveyable size for further processing.

Flux de travail opérationnel:
1. Consommation alimentaire: Large feed material is directed into the crushing chamber via a feed hopper and spider.
2. Concassage compressif: The mantle gyrates within the concave liners, applying compressive force to break particles against themselves and the chamber walls.
3. ​Réduction progressive: Material travels down the chamber, undergoing repeated compression until it reaches the required discharge size.
4. Décharge: Crushed product exits through the discharge opening at the bottom of the crusher, dictated by the closedside setting (CSS).

Champ d'application & Limites:
Portée: Idéal pour les tonnages élevés (typiquement >1,000 tph) extraction de roche dure (cuivre, minerai de fer), carrières de granulats à grande échelle, et traitement industriel des minéraux. Conçu pour une utilisation continue, 24/7 opération.
Limites: Not suitable for lowtonnage operations due to high capital cost. Less effective on highly abrasive materials without specific liner metallurgy. Nécessite une écurie, reinforced concrete foundation and significant headroom for installation and maintenance.

3. CARACTÉRISTIQUES PRINCIPALES

Conception concave brevetée | Base technique: Segmenté, chaussons réversibles au profil optimisé | Avantage opérationnel: Increases service life by up to 30%, allows for rotation of segments to utilize full wear life evenly | Impact sur le retour sur investissement: Reduces liner inventory costs and frequency of changeouts, réduire le coût du coût

Régulation de réglage automatique intégrée | Base technique: Hydraulic piston coupled with position sensors | Avantage opérationnel: Enables realtime CSS adjustment under load for consistent product grading; facilitates automatic overload protection (libération des clochards) | Impact sur le retour sur investissement: Maintains optimal throughput and protects downstream equipment from damage, maximiser la disponibilité de l'usine

Superior Spider & Conception de la bague | Base technique: Largediameter alloy steel bushings with centralized lubrication | Avantage opérationnel: Provides exceptional stability to the main shaft under shock loads, minimizing vibration and wear on critical components | Impact sur le retour sur investissement: Prolonge la durée de vie des principaux composants, reduces risk of catastrophic failure requiring extended downtime

StateMonitored Lube System | Base technique: Filtration unit with flow, température, and pressure sensors tied to plant control system | Avantage opérationnel: Assure une lubrification optimale des roulements; provides early warning diagnostics for potential issues before they cause damage | Impact sur le retour sur investissement: Empêche les défaillances coûteuses des roulements; enables predictive maintenance scheduling versus reactive repairs

Philosophie de conception de TopService | Base technique: All routine service tasks accessible from above via removable arms/spider | Avantage opérationnel: Eliminates the need for personnel to work beneath suspended components; simplifies liner change procedures significantly | Impact sur le retour sur investissement: Reduces safety risks, shortens planned maintenance downtime by up to 50%, lowering labor hours

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | [Nom du fabricant] Solution de concasseur giratoire | Avantage (% amélioration) |
| : | : | : | : |
| Temps de changement de doublure (Majeur) | 48 72 heures | 24 36 heures | ~50 % plus rapide |
| Consommation d'énergie spécifique (kWh/t) | Varie selon le minerai; référence = X kWh/t| Field data shows reductions of X15% kWh/t| Jusqu'à 15% plus efficace |
| Disponibilité (Entretien programmé) | ~9294% availability target| Réalise >96% availability in documented cases| >2 augmentation en points de pourcentage |
| Coût total de possession (5estimation de l'année)| Based on standard liner life/energy use| Lower consumable cost + energy savings = reduced TCO| Estimé 1018% coût total de possession inférieur |

5. SPÉCIFICATIONS TECHNIQUES

Gamme de modèles & Capacité: Series includes models from 4265 à 60113 (feed opening x mantle diameter in inches). Les capacités vont de 2,000 mtph à plus 10,000 mtph, dependent on ore characteristics and closedside setting.
Exigences d'alimentation: Installed motor power from 300 kW jusqu'à 1 MW. Drive system includes heavyduty AC motor,Vbelt drive or direct drive options,and gear & pinion set.
Spécifications matérielles: Main frame constructed from highstrength,welded steel plate. Concave liners available in alliages d'acier au manganèse, with optional chrome white iron or composite materials for highly abrasive applications.
Dimensions physiques & Poids: Total installed height ranges from ~6m to >9m. Total operating weight can exceed 400 tonnes, requiring detailed foundation engineering.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 40°C à +50°C. Les joints anti-poussière protègent les mécanismes internes; systems can be configured for dusty or wet environments.

6. SCÉNARIOS D'APPLICATION

Expansion d’une mine de cuivre à grande échelle

Défi: A tierone copper operation needed to debottleneck its primary circuit to meet increased throughput targets of 25%. The existing gyratory crusher required frequent liner changes that caused production delays.
Solution: Mise en œuvre d'un [Nom du fabricant] 6089 Gyratory Crusher featuring the patented concave design and topservice layout.
Résultats: Nous avons obtenu une augmentation soutenue du débit de 28%. Liner service life improved by 22%, reducing annual consumable costs by an estimated $180k. Planned maintenance time was reduced by 40%.

Carrière de granulats à haute abrasion

Défi: A granite quarry faced prohibitively high wear costs and inconsistent product gradation due to variable feed hardness in its primary crushing stage.
Solution: Installation of a specially configured gyratory crusher with composite liners in key wear zones and integrated automatic setting regulation.
Résultats: Wear part costs per ton were reduced by 18%. The automatic regulation maintained product gradation within a ±5mm specification over 95% du temps de fonctionnement, improving downstream screening efficiency.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Capital pricing is modeldependent based on size/capacity tier (par ex., MediumCapacity Range vs SuperDuty Range). Pricing includes crusher assembly,moteur,and drive guards.Base installation engineering support is typically included.
Fonctionnalités facultatives / Forfaits:
Package d'automatisation avancée (includes remote monitoring/adjustment)
Special Wear Material Package (alliages haut de gamme)
Modular Maintenance Tool Kit
Extended Environmental Protection Package
Forfaits de services: Offert sous forme de contrats annuels couvrant les inspections programmées,lube system servicing,and priority technical support.Tiered levels provide varying degrees of parts coverage/discounts.
Financing Options Available through manufacturer's financial services division include traditional capital lease,taxoriented lease structures,and projectbased financing solutions tailored for large capital expenditures.

8\. FAQ

1\. Q How does this gyratory crusher integrate with our existing plant control system?
A The crusher's PLCbased control system is designed with standard communication protocols (par ex., Modbus TCP/IP). It can be integrated as a subsystem within your wider SCADA/DCS network,facilitating centralized monitoring.

2\. Q What is the expected impact on our overall plant energy consumption?
A Field data shows that due to optimized kinematics and efficient drive design,the specific energy consumption per ton crushed can be lower than older designs.An energy audit during project planning can provide sitespecific projections.

3\. Q Are there financing options that align with our project's cash flow requirements?
A Yes.Financing structures are available that can match payments with project rampup phases or offer seasonal payment plans aligned with production cycles.Detailed proposals require review of project specifics.

4\. Q What level of technical support is provided during commissioning?
A Standard commercial terms include supervised commissioning conducted by factorytrained engineers.This encompasses initial startup,étalonnage du système,and operator training over a defined period.

5\. Q Can this equipment handle our specific ore type which has both high hardness and abrasiveness?
A Our engineering team conducts application reviews using provided ore characteristics.We specify liner metallurgy profiles accordingly.Options like hybrid composite liners are available specifically for such challenging conditions.

6\. Q What are typical lead times from order placement to delivery?
A Lead times vary by model complexity.Current standard lead times range from X months.For critical path projects,"fasttrack" manufacturing slots may be available subjectto inquiry.

7\. Q How does your warranty structure address major components like the main shaft or eccentric assembly?
A The standard warranty covers defects in materials/workmanship.A separate,bonded warranty extensionfor major structural componentsis often available as an option providing defined coverage terms