1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? Key challenges in primary gyratory crusher operation directly impact your bottom line:
Temps d'arrêt excessif pour la maintenance: Traditional spider arm and top shell designs require complex, timeconsuming procedures for wear part replacement, leading to production losses of several days.
Unplanned Stoppages from Tramp Iron: Inadequate protection mechanisms can result in catastrophic damage from uncrushable material, with repair costs exceeding hundreds of thousands and causing extended outages.
Débit incohérent & Product Gradation: Worn or poorly designed crushing chambers fail to maintain optimal feed acceptance and product size control, bottlenecking downstream processes and reducing final product yield.
Consommation d'énergie élevée par tonne: Inefficient crushing action and excessive friction from outdated mechanical designs lead to unsustainable power costs, a major operational expenditure.

Is your operation equipped to overcome these challenges? The solution lies in a modern gyratory crusher engineered for reliability, efficacité, and lower total cost of ownership.

2. APERÇU DU PRODUIT: BROYEUR GIRATOIRE

A gyratory crusher is a primary compression crusher central to hightonnage mining and aggregate operations. It utilizes a fixed conical shell (concave) and a gyrating mantle mounted on an eccentric shaft to reduce large runofmine (ROM) feed material down to a conveyable size.

Flux de travail opérationnel:
1. Acceptation des aliments: ROM material is fed into the top of the crusher via dump trucks, chargeurs, or a primary feeder, entering the gap between the mantle and concave.
2. Concassage compressif: Le manteau tourne dans le concave, applying compressive force to the rock particles against the stationary liners.
3. Réduction progressive: Le matériau est broyé en continu à mesure qu'il descend dans la chambre en raison de la gravité et de l'action de concassage..
4. Décharge: Crushed product exits at the bottom through the discharge opening (OSS), where it is transported via conveyor for secondary processing.

Champ d'application & Limites:
Portée: Idéal pour les grandes capacités (1,000+ TPH) primary crushing of hard, minerais abrasifs (minerai de fer, minerai de cuivre) and large aggregate feed. Convient aux installations d'usines stationnaires.
Limites: Not designed for recycled concrete/asphalt or lowtonnage applications. Requires significant capital investment and a robust foundation. Feed size must be controlled within design parameters.

3. CARACTÉRISTIQUES PRINCIPALES

Patented Top Service Design | Base technique: Simplified mechanical access from above | Avantage opérationnel: Enables liner changes and maintenance in 2448 hours versus 57 jours | Impact sur le retour sur investissement: Reduces planned downtime by over 60%, augmentation du temps de production annuel disponible

Integrated Automatic Tramp Release System | Base technique: Les vérins hydrauliques soutiennent l'arbre principal | Avantage opérationnel: Automatically lowers the main shaft to pass tramp iron, then resets without stopping | Impact sur le retour sur investissement: Eliminates costly damage from uncrushables; prevents an average of 35 days of unplanned downtime annually

Optimized Crushing Chamber Profiles | Base technique: Computermodeled kinematics and wear simulation | Avantage opérationnel: Maintains consistent feed acceptance and product gradation throughout liner life | Impact sur le retour sur investissement: Improves overall circuit throughput stability by 58% and extends liner service life by 1525%

HighPower Drive & Robust Eccentric Assembly | Base technique: Hightorque motor coupled with a forged alloy steel eccentric | Avantage opérationnel: Delivers consistent crushing force under peak loading conditions with minimal vibration | Impact sur le retour sur investissement: Provides higher availability (>94%) and reduces stressinduced component failures

Système de lubrification automatisé centralisé | Base technique: Programmable PLCcontrolled lubrication to all critical bearings | Avantage opérationnel: Ensures optimal bearing temperature and health; provides diagnostic alerts | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements jusqu'à 30% and prevents lubricationrelated stoppages

StateoftheArt Control System (ICS) | Base technique: Surveillance en temps réel de la consommation électrique, pression, température, et niveau de la cavité | Avantage opérationnel: Allows operators to optimize performance and receive predictive maintenance alerts | Impact sur le retour sur investissement: Increases operational efficiency by 35% through precise control; enables conditionbased maintenance planning

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Older Gyratory Designs) | Modern Gyratory Crusher Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Planned Maintenance Time (Spider Arm/Liners) | 120 168 heures | 48 72 hours with Top Service Design| 60% Réduction |
| Disponibilité mécanique (Annuel) | 88 91%| >94% (moyenne de terrain documentée)| 36% Augmenter |
| Liner Utilization (Tonnes/Liner KG)| Référence| Conception de chambre optimisée & matériels| 1525% Amélioration|
| Consommation d'énergie (kWh/tonne)| Référence| Efficient drive & chamber kinematics| 510% Réduction |
| Tramp Iron Damage Events / Année| 0.5 1 event (moy.)| Nearzero with automatic system| >95% Réduction |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 1,500 à plus 12,000 tonnes par heure (TPH), depending on model chamber selection and feed material.
Puissance du moteur: Heavyduty squirrel cage induction motors ranging from 450 kW à plus 1 MW.
Ouverture d'alimentation: Tailles d'ouverture de 1,000 mm jusqu'à 1,800 mm for handling large ROM feed.
Cadre principal & Concaves: Fabricated highstrength steel main frame; concaves available in manganese steel or composite alloy designs for specific abrasion/impact conditions.
Dimensions & Poids: Significant footprint; approximate installed weight ranges from 250 tonnes for smaller models to over 800 tonnes for largest units.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 40°C à +50°C avec des systèmes de lubrification appropriés. L'étanchéité à la poussière est standard.

6. SCÉNARIOS D'APPLICATION

Expansion d’une mine de cuivre à grande échelle

Défi: A tierone copper operation needed to increase plant throughput by 25%. Their existing primary gyratory was a bottleneck with frequent liner change downtime exceeding one week.
Solution: Installation of a new highcapacity gyratory crusher featuring top service design and an automated tramp release system.
Résultats: Achieved sustained throughput increase of 28%. Planned maintenance time reduced by approximately five days per event. Zero unplanned downtime due to tramp metal in the first two years of operation.

Granite Aggregate Quarry Upgrade

Défi: A quarry producing railway ballast faced inconsistent product gradation as liners wore, leading to excessive recirculating load in their secondary circuit.
Solution: Implementation of a midrange gyratory crusher with computeroptimized crushing chamber profiles linked to an advanced control system (ICS).
Résultats: Product gradation remained within specification throughout >90% of liner life. Recirculating load decreased by an average of 15%, reducing energy consumption in the secondary cone crushers.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Capital cost varies significantly based on size/capacity:
MidRange Units (6,000 TPH): For major greenfield or expansion projects in bulk mining.

Fonctionnalités facultatives & Mises à niveau: Systèmes avancés de surveillance de l’usure; specialized liner alloys for specific ore types; upgraded filtration systems for extreme environments; remote diagnostics connectivity.

Forfaits de services: Tiered offerings include:
Garantie de base & Parts Support
Planned Maintenance Agreements with guaranteed parts supply
FullPerformance Contracts covering parts AND labor with availability guarantees

Options de financement: Projectspecific financing through manufactureraffiliated programs can include leasetoown structures or extended payment terms aligned with project rampup milestones.

8. FAQ

T1: Is this equipment compatible with our existing primary feeding system?
A compatibility review is standard during project engineering analysis based on your feeder type capacity hopper design We provide detailed interface specifications

Q2 Quel est l'impact attendu sur la consommation énergétique globale de notre usine?
Field data shows modern drives optimized chambers can reduce specific energy kWh tonne crushed by This contributes directly lower operating costs

Q3 Are there financing options available beyond standard purchase?
Yes we offer several commercial structures including operating leases long term payment plans tailored large capital projects Consult our commercial team details

Q4 How does implementation typically affect ongoing personnel training?
We provide comprehensive onsite operator maintenance training documentation ensure your team achieves proficiency safe efficient operation quickly minimize transition disruption

Q5 What are lead times typical delivery installation schedule?
Lead times vary model specification current demand but generally range months Detailed project schedule developed during pre order engineering phase account site preparation logistics commissioning