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? Pour les directeurs d’usine et les entrepreneurs en ingénierie, the primary crushing stage is a critical bottleneck where inefficiencies cascade through the entire processing line. Common challenges with outdated or underperforming primary crushers include:

Temps d'arrêt excessif pour la maintenance: Des changements fréquents de revêtement et des pannes mécaniques inattendues peuvent interrompre l'ensemble de vos opérations., coûtant des milliers de dollars par heure en perte de production.
Coûts opérationnels élevés: Rising energy consumption per ton of processed material and the laborintensive nature of routine servicing directly impact your bottom line.
Gestion incohérente des aliments & Débit: Pontage, uneven feed distribution, and inability to handle variable ore hardness lead to suboptimal capacity and product size distribution.
Défaillance prématurée des pièces d’usure: Improper crushing chamber design leads to accelerated abrasion on mantles and concaves, driving up your costperton for consumables.

Is your current primary crusher delivering the reliable throughput and predictable operating cost required in today's market? The solution lies in selecting a gyratory crusher engineered to address these exact pain points.

2. APERÇU DU PRODUIT: BROYEUR GIRATOIRE

A gyratory crusher is a stationary compressive crushing unit central to hightonnage mining and aggregate operations. It is designed for firststage, primary crushing of runofmine ore or blasted quarry rock into a size suitable for conveyor transport and secondary processing.

Flux de travail opérationnel:
1. Consommation alimentaire: Large dump trucks or loaders deposit material into the topmounted feed hopper.
2. Action écrasante: The central shaft, fitted with a mantle, gyrates within a stationary concave liner. The eccentric motion creates a progressive compressive crushing action.
3. Décharge du produit: Crushed material falls by gravity through the narrowing gap at the bottom of the chamber (the closedside setting) onto a discharge conveyor.

Champ d'application: Ideal for very highcapacity applications (typiquement >1,000 tph) requiring continuous operation on hard, matériaux abrasifs comme le granit, minerai de fer, and copper ore.

Principales limites: Requires a stable, reinforced concrete foundation. Coût d'investissement initial plus élevé que celui des grands concasseurs à mâchoires. Ne convient pas aux usines portables ou aux opérations à faible tonnage.

3. CARACTÉRISTIQUES PRINCIPALES

Profil concave breveté | Base technique: Optimized nip angle & crushing chamber geometry | Avantage opérationnel: Promotes interparticle crushing for finer initial product size & reduces slabby output | Impact sur le retour sur investissement: Réduit la charge sur les circuits en aval jusqu'à 15%, lowering overall system energy cost.

Système de contrôle intelligent intégré | Base technique: Realtime pressure & position sensors with PLC automation | Avantage opérationnel: Automatically compensates for liner wear & adjusts for optimal power draw | Impact sur le retour sur investissement: Maintains consistent throughput & taille du produit, maximizing yield over full liner life.

TopService Design | Base technique: Simplified maintenance access from above the crusher | Avantage opérationnel: Permet de sécuriser, rapid mantle changeouts without personnel entering the pit | Impact sur le retour sur investissement: Réduit les temps d'arrêt pour maintenance planifiée jusqu'à 30% versus traditional designs.

Hydroset® Tramp Release & Setting Adjustment | Base technique: Hydraulic cylinders support the main shaft | Avantage opérationnel: Allows remote adjustment of CSS for product control & automatically releases tramp iron | Impact sur le retour sur investissement: Protects against costly damage events; enables process adjustments in minutes vs. heures.

Lube System with Filtration & Surveillance | Base technique: Dualcircuit oil circulation with temperature control | Avantage opérationnel: Ensures consistent bearing lubrication under high load; extends component life | Impact sur le retour sur investissement: Empêche les défaillances catastrophiques des roulements; les données de terrain montrent un 40% augmentation du temps moyen entre pannes (MTBF).

HeavyDuty Spider & Mainframe Casting | Base technique: Highstrength alloy steel with computervalidated design | Avantage opérationnel: Provides structural integrity to withstand decades of highload cyclic stress | Impact sur le retour sur investissement: Eliminates risk of frame fatigue failure; ensures longterm asset integrity over a 30+ année de vie.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Moyenne) | Notre solution de concasseur giratoire | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité (Temps de disponibilité) | 92 94% | 96%+ (documenté) | +35% |
| Efficacité énergétique (kWh/tonne) Baseline = Hard Granite| 0.8 1.0 kWh/t| 0.65 0.75 kWh/t| 18% |
| Durée de vie du revêtement (Million Tonnes Processed) Varie selon le matériau| Sitespecific; often inconsistent| Extended by patented profile & alloy| +1525% |
| Temps moyen de réparation (MTTR Mantle Change)| 24 36 heures| <18 heures| 33% |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 2,000 à plus 10,000 tonnes par heure (tph), selon le modèle et le matériau d'alimentation.
Motor Power Requirement: Typically from 450 kW jusqu'à 1,200 kW (600 1,600 HP), supplied at either medium voltage (par ex., 6.6kV) or low voltage.
Ouverture d'alimentation: Tailles d'ouverture de 1,000 mm à 1,500 mm standard.
Spécifications matérielles: Mainframe constructed from normalized steel castings; concaves and mantles available in premium manganese steel alloys or composite metal matrix options.
Dimensions physiques / Empreinte: Varie selon le modèle; example model requires ~7m x ~7m foundation area excluding feed hopper.
Plage de fonctionnement environnementale: Designed for ambient temperatures from 40°C to +50°C with appropriate lubrication systems and housing options.

6. SCÉNARIOS D'APPLICATION

Expansion d’une mine de cuivre à grande échelle

Challenge A major South American operation needed to increase plant throughput by 25%. Their existing primary circuit was unreliable, causing frequent bottlenecks and unpredictable maintenance shutdowns.
Solution Installation of two new heavyduty gyratory crushers with intelligent control systems as the cornerstone of their expansion project.
Results Achieved sustained throughput of over 6 ,500 tph each . Plant availability increased by 4 .2 % , meeting expansion targets while reducing specific energy consumption by 0 .15 kWh/t .

HighAbrasion Aggregate Quarry

Challenge A North American granite quarry faced unsustainable costs due to premature wear part failure every 6 –8 weeks , alongside high energy bills .
Solution Replaced an older crusher with a modern gyratory unit featuring our advanced concave profile and optional metal matrix liners .
Results Liner life extended to an average of 14 semaines . La consommation d'énergie par tonne a diminué de 19 % . The resulting lower costperton secured a key longterm supply contract .

7. CONSIDÉRATIONS COMMERCIALES

Our gyratory crushers are offered in structured pricing tiers based on size capacity and feature sets:

Série de service standard: For consistent , nonabrasive feeds . Includes core reliability features .
Heavy Duty Series ( Recommended for most mining applications ) : Comprend toutes les fonctionnalités répertoriées dans la section 3 , with enhanced wear packages .
Extreme Duty Series: For maximum abrasion resistance , includes premium alloys , advanced monitoring sensors , and extended warranty .

Optional features include dust suppression seals , systèmes de lubrification automatisés , and advanced predictive maintenance sensor packages .

We offer comprehensive service agreements covering planned maintenance , parts supply at preferential rates , et 24 /7 remote technical support . Financing options including leasetoown structures and projectbased capital expenditure plans are available through our partners .

8.FAQ

Q What are the foundation requirements for installing this equipment ?
A Detailed geotechnical specifications are provided . Generally it requires a significant mass of reinforced concrete ; our engineering team supplies full foundation drawings and load data .

Q How does this equipment integrate with our existing PLC / SCADA system ?
A The intelligent control system uses standard industrial communication protocols( par ex., Modbus TCP/IP , OPC UA ) allowing seamless data integration into your plantwide control room .

Q What is the typical delivery lead time ?
A Lead times vary by model specification but generally range from 9 –14 months exworks due to heavy casting requirements . We maintain critical spare parts inventory regionally .

Q Can you provide assistance during commissioning ?
A Yes we include supervised commissioning as standard along with comprehensive operator training programs conducted at your site .

Q What financing options are available ?
A We work with several equipment finance specialists offering operating leases capital leases or tailored purchase plans typically ranging from 3 –7 years .

Q How do you guarantee performance ?
A Performance guarantees for capacity power drawand product sizingare contractually established based on agreed feed material characteristicsand site conditions

Q Are wear parts readily available ?
A We maintaina global networkof certified parts warehouses ensuring availability Critical wear partslike mantleand concave kitsare often stocked regionallyfor rapid dispatch