Concasseur giratoire certifié ISO

1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Every hour of unscheduled downtime in your primary crushing circuit costs between $15,000 et $50,000 en production perdue. If your current gyratory crusher is experiencing frequent spider bushing failures, inconsistent mantle wear patterns, or throughput bottlenecks below 1,500 MTPH, you are bleeding margin on every ton. Plant managers report that outdated crusher designs require 1218 hours for a mantle change, pushing maintenance crews into overtime and increasing safety risks. Engineering contractors face the challenge of integrating a crusher that must handle feed sizes up to 1,500mm while maintaining a P80 product of 150200mm without constant adjustment. Is your current equipment delivering the mechanical availability of 95%+ that your quarterly targets demand?

2. APERÇU DU PRODUIT

The ISO Certified Gyratory Crusher is a primary compression crusher engineered for highcapacity reduction of hard rock and ore. It operates on a fixed spindle design with a rotating eccentric assembly, delivering continuous crushing action.

Flux de travail opérationnel:

• Entrée de flux: Matériel tout-venant (up to 1,500mm) enters the crushing chamber via a feed cone and spider assembly.
• Rotation excentrique: UN 500700 RPM eccentric sleeve rotates the main shaft, creating a gyrating motion against the concave liners.
• Concassage par compression: Material is crushed between the mantle and concave in a continuous downward spiral, reducing particle size.
• Décharge: Produit broyé (typiquement 80% passing 150200mm) exits through the bottom of the chamber into a discharge hopper.
• Réglage hydraulique: Hydroset system adjusts the crusher setting (CSS) remotely to compensate for wear or change product size.

Champ d'application: Primary crushing in hard rock mining (cuivre, or, minerai de fer), carrières de granulats, and largescale cement operations. Limites: Not suitable for sticky or clayrich materials exceeding 8% teneur en humidité; requires a minimum feed size of 300mm to maintain chokefed conditions.

3. CARACTÉRISTIQUES PRINCIPALES

Chambre de concassage haute capacité | Base technique: Deepbowl profile with optimized nip angle (2224 degrés) | Avantage opérationnel: Accepts larger feed (up to 1,500mm) while maintaining consistent product gradation | Impact sur le retour sur investissement: Reduces need for secondary blasting, économie $0.15$0.30 per ton in drilling and explosives costs

SplitShell Main Shaft Design | Base technique: Twopiece shaft assembly with interference fit | Avantage opérationnel: Enables insitu shaft replacement without removing the top shell, réduisant les temps d'arrêt en 40% | Impact sur le retour sur investissement: Cuts maintenance labor hours by 6080 hours per major service event

Hydroset Hydraulic Adjustment System | Base technique: Nitrogencharged accumulator with electronic position sensor | Avantage opérationnel: Provides realtime CSS adjustment from the control room, élimination du calage manuel | Impact sur le retour sur investissement: Augmente le débit de 58% by maintaining optimal crusher setting during liner wear

Bronze Spider Bushing with Grease Lubrication | Base technique: Highleaded bronze alloy (SAE 660) with automatic grease injection | Avantage opérationnel: Extends bushing life to 8,00010,000 operating hours in dusty environments | Impact sur le retour sur investissement: Reduces bushing replacement costs by $12,000$18,000 per year per unit

DualAction Tramp Iron Relief | Base technique: Hydraulic cylinders with pressure relief valves set at 120% de pression de fonctionnement | Avantage opérationnel: Passe les matériaux incassables (fer à repasser) without damaging the main frame or eccentric | Impact sur le retour sur investissement: Empêche les pannes catastrophiques, économie $250,000+ in potential main frame replacement

OIN 9001:2015 Fabrication certifiée | Base technique: Full traceability from raw material to final assembly, with ultrasonic testing on all castings | Avantage opérationnel: Guarantees consistent metallurgy and dimensional accuracy across all components | Impact sur le retour sur investissement: Réduit les réclamations au titre de la garantie de 90% et prolonge la durée de vie de 1520%

Système de doublure modulaire | Base technique: Interchangeable concave segments with wedgelock retention | Avantage opérationnel: Allows partial liner replacement (haut, milieu, bottom rows) without removing entire set | Impact sur le retour sur investissement: Redesigned liner changeout time from 18 heures pour 8 heures, économie $80,000 in lost production per event

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (6089" Giratoire) | Concasseur giratoire certifié ISO | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité mécanique | 8892% | 9597% | +58% |
| Débit (MTPH) | 1,2001,800 | 1,5002,200 | +1522% |
| Temps d'ajustement CSS | 4560 minutes (manuel) | 25 minutes (hydraulique) | 90% |
| Mantle Life (heures) | 4,0006,000 | 6,0008,500 | +3042% |
| Consommation d'énergie (kWh/t) | 0.350.50 | 0.280.40 | 1520% |
| Coût d'entretien ($/tonne) | $0.08$0.12 | $0.05$0.08 | 3035% |

5. SPÉCIFICATIONS TECHNIQUES

| Paramètre | Spécification |
| : | : |
| Gamme de modèles | GY42 (1,067mm) to GY89 (2,260mm) |
| Plage de capacité | 1,200 2,200 MTPH (depending on model and CSS) |
| Taille maximale d'alimentation | 1,500mm (GY89 model) |
| Taille du produit (P80) | 150250mm (réglable via CSS) |
| Exigence de puissance | 250 kW (GY42) à 1,200 kW (GY89) |
| Vitesse du moteur | 500700 RPM (excentrique) |
| Matériau de l'arbre principal | Acier allié forgé (AISI 4340) |
| Concave/Mantle Material | 18% Acier au manganèse (ASTM A128 Catégorie C) |
| Système de lubrification | Forced oil circulation (200400 L/min) |
| Pression hydraulique | 140210 bar (Système hydroset) |
| Plage de température de fonctionnement | 20°C à +50°C |
| Poids (complete unit) | 120,000 kilos (GY42) à 450,000 kilos (GY89) |
| Certification ISO | OIN 9001:2015, OIN 14001:2015 |

6. SCÉNARIOS D'APPLICATION

Copper Mine – Open Pit Primary Crushing | Défi: Existing 60" gyratory was bottlenecking throughput at 1,400 MTPH, with weekly spider bushing failures due to high silica content (15% SiO2) | Solution: Installed ISO Certified GY72 gyratory crusher with upgraded bronze bushings and dual tramp iron relief | Résultats: Le débit a augmenté à 1,850 MTPH (32% amélioration); bushing life extended from 2,000 à 7,500 heures; mechanical availability rose from 89% à 96%

Iron Ore Mine – Primary Crushing Circuit | Défi: High wear rates on concave liners (3,000hour life) due to abrasive hematite (Mohs 6.5); maintenance costs exceeded $0.15/ton | Solution: Deployed GY60 model with modular liner system and 18% acier au manganèse | Résultats: Liner life increased to 6,200 heures (107% amélioration); maintenance cost reduced to $0.07/ton; liner changeout time dropped from 18 à 9 heures

Aggregate Quarry – Hard Granite | Défi: Classement incohérent des produits (P80 varied from 180250mm) causing downstream cone crusher inefficiency | Solution: GY42 crusher with Hydroset system and realtime CSS monitoring | Résultats: Product P80 stabilized at 175mm ±10mm; downstream cone crusher throughput increased by 12%; overall plant energy consumption reduced by 0.08 kWh/tonne

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification des équipements (Port FOB, Hors installation):

• GY42 (1,067mm): $850,000 $1,100,000
• GY60 (1,524mm): $1,600,000 $2,100,000
• GY72 (1,829mm): $2,400,000 $3,200,000
• GY89 (2,260mm): $3,800,000 $5,000,000

Fonctionnalités facultatives:

• Automated lubrication system with remote monitoring: +$45,000
• Revêtements composites en céramique (pour une abrasion extrême): +$120,000
• Vibration monitoring package (4channel): +$35,000
• Système de suppression de poussière (pulvérisation d'eau): +$28,000

Forfaits de services:

• Basique (12 mois): Garantie + assistance technique à distance ($15,000/année)
• Standard (36 mois): Garantie + 2 site inspections/year + kit de pièces de rechange ($45,000/année)
• Prime (60 mois): Full coverage + 4 inspections de chantier + rapports de maintenance prédictive + 10% discount on parts ($85,000/année)

Options de financement:

• Location-propre: 3660 termes de mois à 4.56.5% AVR (sous réserve d'approbation de crédit)
• Paiement différé: 10% vers le bas, 90% dû après 90 jours de vérification des performances
• Programme d'échange: Accepting qualified used gyratory crushers (6089") at appraised value up to $500,000

8. FAQ

Q: Can this ISO Certified Gyratory Crusher be retrofitted into an existing foundation from another manufacturer?
UN: Oui. The base frame footprint is compatible with most 6089" gyratory crusher foundations. We provide a foundation adapter kit (included in pricing) that accommodates bolt patterns from AllisChalmers, Racines, and Sandvik models. A site survey is recommended to verify dimensions.

Q: What is the expected lead time from order to delivery?
UN: Le délai de livraison standard est 1620 weeks for GY42 and GY60 models, et 2430 weeks for GY72 and GY89 models. Commandes urgentes (1214 semaines) sont disponibles avec un 15% frais d'accélération, subject to foundry capacity.

Q: How does the Hydroset system handle power outages?
UN: The system includes a nitrogencharged accumulator that maintains hydraulic pressure for up to 8 heures. For extended outages, a manual hand pump allows CSS adjustment. An optional backup battery pack (12V) fournit 4 hours of electronic control operation.

Q: What is the recommended maintenance schedule for the eccentric assembly?
UN: Inspect eccentric bearings every 500 heures d'ouverture. Replace grease and check oil filters every 1,000 heures. Major eccentric overhaul is recommended at 12,00015,000 heures, depending on operating conditions. Field data shows average eccentric life of 18,000 hours in hard rock applications.

Q: Does the crusher meet environmental noise regulations?
UN: Oui. Sound levels at 1 meter distance are 8590 dB(UN) sous charge, compliant with OSHA and EU directives. An optional acoustic enclosure reduces noise to 75 dB(UN) and is recommended for urban or noisesensitive sites.

Q: Quelle formation proposez-vous aux opérateurs d'usine?
UN: Nous proposons un programme de formation sur site de 3 jours couvrant les procédures de démarrage, Ajustement CSS, surveillance de l'usure du revêtement, et protocoles d'arrêt d'urgence. Training includes a digital manual with video tutorials. Remote refresher sessions are available quarterly.

Q: Can this crusher handle highclay content ore?
UN: The standard design is optimized for dry to moderate moisture (jusqu'à 5% teneur en humidité). For highclay ore (58% humidité), we recommend the optional anticlog spider arm design and heated discharge chute. Au-dessus de 8% humidité, a feederbreaker or sizer is more appropriate.