1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Temps d'arrêt imprévu, rising maintenance costs, and inconsistent throughput are critical pressures in primary crushing. When a gyratory crusher underperforms or fails, the financial impact cascades through your entire operation. Are you managing frequent liner changes that halt production for days? Are power spikes and uneven feed causing premature component wear and unpredictable output gradation? Is the total cost of ownership for your primary crushing station exceeding projections due to unplanned repairs and energy inefficiency? These operational challenges directly affect your plant’s availability, budget, and longterm profitability.

2. APERÇU DU PRODUIT

The modern heavyduty gyratory crusher is engineered as a primary crushing solution for hightonnage mining and aggregate operations. It is designed to handle runofmine ore or large quarry rock at the initial size reduction stage.

Flux de travail opérationnel:
1. Consommation alimentaire: Large dump trucks or loaders deposit material directly into the crusher’s spacious feed hopper.
2. Action écrasante: Le manteau central tourne dans un concave stationnaire, appliquer une force de compression pour réduire le matériau en le pressant contre les parois de la chambre.
3. Décharge: Crushed product exits through the bottom of the crushing chamber via the adjustable discharge setting, which controls final product size.

Champ d'application & Limites:
Portée: Idéal pour les grandes capacités (1,000+ TPH) primary crushing of abrasive materials like granite, minerai de fer, et minerai de cuivre. Suited for stationary installations with continuous feed.
Limites: Not designed for smallscale operations or highly mobile plants due to significant capital cost, large physical footprint, and complex installation requirements. Moins efficace pour les produits non abrasifs, lowtonnage applications where a jaw crusher may be more economical.

3. CARACTÉRISTIQUES PRINCIPALES

Conception d'araignée brevetée | Base technique: Multiarm forged steel construction with optimized bearing seats | Avantage opérationnel: Provides superior load distribution and alignment for the main shaft, reducing stress concentrations | Impact sur le retour sur investissement: Extends service life of critical components by up to 20%, lowering longterm capital expenditure.

Automatisation intelligente de la chambre | Base technique: Hydraulic adjustment and setting regulation via PLC control system | Avantage opérationnel: Permet aux opérateurs d'ajuster le CSS (Réglage du côté fermé) under load and monitor chamber conditions in realtime | Impact sur le retour sur investissement: Maintains optimal product gradation with less manual intervention, increasing yield consistency by an average of 8%.

Système d'amélioration de la durée de vie du revêtement | Base technique: Computeroptimized concave and mantle profiles with wear material analysis | Avantage opérationnel: Ensures more uniform wear distribution across crushing surfaces, maximizing metal utilization | Impact sur le retour sur investissement: Réduit la fréquence de changement de doublure de 1530%, directly decreasing labor costs and associated downtime.

Entraînement direct & Limitation de couple | Base technique: Moteur synchrone basse vitesse couplé directement à l'ensemble excentrique | Avantage opérationnel: Eliminates Vbelt slippage losses and provides high starting torque; integrated hydraulic torque limiter protects against tramp iron | Impact sur le retour sur investissement: Améliore l'efficacité de la transmission d'énergie d'environ 5% and prevents catastrophic damage from uncrushable material.

Étanchéité anti-poussière intégrée & Lubrification | Base technique: Positivepressure labyrinth seal system with automated grease injection; dedicated forcedfeed lubrication circuit | Avantage opérationnel: Effectively excludes contaminants from bearings and ensures constant oil film on critical surfaces | Impact sur le retour sur investissement: Reduces bearingrelated failures by over 40%, a leading cause of major crusher stoppages.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Notre solution de concasseur giratoire | Avantage documenté |
| : | : | : | : |
| Disponibilité (Temps de disponibilité) | 92 94% moyenne annuelle | Réalise systématiquement >96% moyenne annuelle| +2 à +4 points de pourcentage |
| Consommation d'énergie spécifique (kWh/tonne) Varie selon le matériau| Ligne de base = 100%| Average reduction to 9295% de la ligne de base| 5% à 8% amélioration |
| Utilisation de la doublure (MetaltoWear Ratio) Varies by profile| Ligne de base = 100%| Réalise 115125% of baseline utilization| +15% à +25% amélioration |
| Temps moyen entre les révisions majeures (MTBMO)| ~60 000 heures de fonctionnement| Cible de >72,000 heures d'ouverture| +20% intervalle d'entretien prolongé |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 1,500 à plus 12,000 tonnes par heure (TPH), dépend du modèle, matière première, et réglage de décharge.
Exigences d'alimentation: Mains connection for heavyduty electric motors ranging from 450 kW à plus 1 MW (600 1,300 HP). Complete drive package includes softstart capability.
Spécifications matérielles: Châssis principal en acier allié à haute résistance; Manganese steel concaves and mantles (various grades available); Arbre principal en acier allié forgé; Bronze bushings in eccentric assembly.
Dimensions physiques: Feed opening diameters from 1,200 mm à 1,800 mm (48" à 72"). La hauteur totale installée peut dépasser 10 mètres; significant foundation engineering is required.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 40°C à +50°C. Les systèmes de suppression de poussière font partie intégrante; seismic design options are available for specific regions.

6. SCÉNARIOS D'APPLICATION

Projet d'agrandissement de la mine de cuivre

Défi: An existing mine’s expansion required a primary crusher capable of processing harder ore at a sustained rate of over 6,000 TPH while fitting into a constrained brownfield footprint with limited maintenance access.
Solution: Installation of a topservice gyratory crusher featuring a compact spider design and automated maintenance tools.
Résultats: The solution achieved required throughput within the spatial constraints. Topservice capability reduced planned liner change duration from 96 heures à moins 72 heures par événement.

Carrière de granit à haute abrasion

Défi: A large aggregate producer faced excessive wear costs and unpredictable liner life in primary crushing, leading to variable product shape and frequent production stoppages.
Solution: Implementation of a gyratory crusher with the proprietary Liner Life Enhancement System and chamber automation.
Résultats: La durée de vie du revêtement a augmenté en moyenne de 22%, stabilizing maintenance schedules. Chamber automation maintained consistent CSS under varying load conditions, improving cubical product yield by approximately 9%.

7. CONSIDÉRATIONS COMMERCIALES

Gyratory crushers represent a major capital investment tiered primarily by size/capacity:
Série de service standard: For capacities up to ~4,000 TPH; suited for large aggregate operations.
Série robuste: For capacities from ~4,000 – 8 ,000 TPH; standard for midtier hard rock mining.
Super Duty Series: For ultrahighcapacity applications exceeding 8 ,000 TPH; engineered for major greenfield mine projects.

Optional features include advanced predictive monitoring sensors (vibrations/température), automated lubrication systems tailored for extreme climates , , , , , , , , , , .

Des forfaits de services complets sont disponibles:
1 . Contrats de maintenance planifiée: Scheduled inspections parts supply discounts .
2 . Performance Contracts: Guaranteed availability uptime metrics .
3 . Assistance technique sur site: Dedicated field service engineers .

Financing options including longterm leasing capital expenditure loans are offered through certified industrial finance partners .

8 . FAQ

Q What factors determine if our operation needs a gyratory versus another type like jaw cone ?
A The decision typically hinges on required throughput abrasiveness feed size Gyratories are optimal sustained very high tonnage (>1000 tph ) continuous hard abrasive materials They generally offer lower cost per tonne capacity but higher initial investment installation complexity compared jaw crushers

Q How does this equipment integrate with our existing plant control system ?
A Modern units come equipped with industrystandard communication protocols Modbus TCP/IP OPC UA allowing direct integration into most SCADA PLC networks This provides centralized monitoring control alarms performance data

Q What is typical installation timeline commissioning process ?
A Installation requires significant foundation work mechanical erection electrical connection Total timeline often ranges months depending site conditions complexity Commissioning involves staged testing empty load full capacity runs supervised our engineers ensure design parameters met before handover

Q Can you quantify expected operational cost savings beyond purchase price ?
A Field data shows dominant savings originate three areas reduced energy consumption (58%) durée de vie prolongée du revêtement (+1525%) increased availability (+24%) Combined these typically contribute faster payback period lower total cost ownership over year lifespan

Q Quelle formation a dispensé notre personnel de maintenance des opérations ?
A We supply detailed operational manuals conduct mandatory onsite training sessions covering safe operation routine maintenance procedures troubleshooting Advanced technical courses available specialized topics like liner change optimization system diagnostics

Q Are spare parts readily available what guarantee supply ?
A We maintain global network regional distribution centers stock critical wear spare parts Supply agreements guarantee availability key components defined service level agreements SLAs minimizing risk extended downtime due parts delay

Q What warranty offered what does cover ?
A Standard warranty covers defects materials workmanship period months operation /xxxx hours whichever first Extended warranties available cover specific components main shaft bearings Additional performance warranties may be included within structured service contracts