1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Les coûts opérationnels croissants et la disponibilité imprévisible érodent-ils la rentabilité de votre circuit de concassage principal ?? Key challenges in gyratory crusher operation directly impact your bottom line:
Temps d'arrêt imprévus: Bearing failures or mainshaft issues can halt entire processing plants for days, costing hundreds of thousands in lost production.
Coûts de maintenance élevés: Fréquent, laborintensive liner changes and component rebuilds consume both budget and critical manpower.
Débit incohérent & Qualité du produit: Worn or poorly designed crushing chambers lead to fluctuating product gradation and reduced capacity, bottlenecking downstream processes.
Consommation d'énergie excessive: Inefficient crushing action and highfriction components result in unsustainable power draw per ton of material processed.

Is your operation managing these recurring issues, or is it time for a crusher engineered to deliver reliability, efficacité, and longterm cost control?

2. APERÇU DU PRODUIT

The Premium Gyratory Crusher represents the pinnacle of primary crushing technology for hightonnage, opérations d'extraction de roches dures et d'agrégats. Conçu pour une utilisation continue, heavyduty service, it is the optimal solution for the initial reduction of runofmine ore or large quarry stone.

Flux de travail opérationnel:
1. Consommation alimentaire: Large dump trucks or loaders deposit feed material directly into the crusher’s robust feed hopper.
2. Action écrasante: The hydraulically supported mainshaft assembly gyrates within a concave crushing chamber, applying compressive force to break material against the chamber walls.
3. Décharge du produit: Crushed material exits through the discharge opening at the bottom of the chamber, avec une taille contrôlée par le réglage du côté fermé (CSS).

Champ d'application & Limites:
Portée: Ideal for primary crushing applications with feed sizes up to 1500mm, requiring capacities from 2,000 à plus 10,000 ème. Suited for abrasive ores (cuivre, or, fer) et granulats de roche dure.
Limites: Not designed for recycled concrete/asphalt or highly plastic/claybound materials. Requires significant capital investment and a stable, fondation en béton armé.

3. CARACTÉRISTIQUES PRINCIPALES

Concave breveté & Mantle Profile | Base technique: Angle de pincement et géométrie de la chambre de concassage optimisés | Avantage opérationnel: Delivers consistent product gradation with fewer fines generation and reduced risk of bridging | Impact sur le retour sur investissement: Improved downstream mill throughput by 37% and lower liner wear cost per ton.

Système de contrôle intelligent intégré | Base technique: Surveillance en temps réel de la consommation électrique, pression, and CSS via IoT sensors | Avantage opérationnel: Enables predictive maintenance alerts and automatic adjustment for optimal performance | Impact sur le retour sur investissement: Réduit les temps d'arrêt imprévus jusqu'à 30% and optimizes energy consumption.

Conception sans araignée & TopService Concept | Base technique: Eliminates the traditional spider assembly; all service is performed from above | Avantage opérationnel: Dramatically reduces liner changeout time from days to hours with smaller crews | Impact sur le retour sur investissement: Increases annual crusher availability by over 200 hours while lowering labor costs.

Forged Alloy Steel Mainshaft | Base technique: Singlepiece forging from highintegrity alloy steel with enhanced fatigue resistance | Avantage opérationnel: Eliminates risk of catastrophic shaft failure under shock loads | Impact sur le retour sur investissement: Avoids multiweek shutdowns and replacement costs exceeding $500k.

Advanced Lube & Système hydraulique | Base technique: Dualcircuit system with automated temperature and contamination control | Avantage opérationnel: Ensures positive pressure in bearings yearround, preventing dust ingress and overheating | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements de 40%, significantly cutting maintenance spend.

HeavyDuty Base & Construction du cadre | Base technique: Analyse par éléments finis (FEA)optimized design using highgrade steel plate | Avantage opérationnel: Absorbs dynamic loads without stress fatigue, ensuring decades of structural integrity | Impact sur le retour sur investissement: Eliminates lifetime costs associated with base repairs or frame cracking.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Premium Gyratory Crusher Solution | Avantage (% amélioration) |
| : | : | : | : |
| Temps de changement de doublure (Ensemble complet) | 72 96 heures | 96%| +24 points de pourcentage |
| Consommation d'énergie spécifique (kWh/t) Varies by material.| Ligne de base = 100%| Industry testing demonstrates a reduction to ~93%| ~7% improvement |
| Durée de vie des roulements (L10) Under equivalent conditions.| ~50,000 hours| Field data shows extension to >70,000 heures| +40% amélioration |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 2,500 à 12,000 tonnes métriques par heure.
Exigences d'alimentation: Valeurs nominales du moteur d'entraînement à partir de 450 kW à plus 1 MW; complete system includes dedicated lube and hydraulic power units.
Spécifications matérielles: Concaves/mantles available in premium manganese steel alloys; critical structural components fabricated from ASTM A36/A572 steel; mainshaft forged from SAE 4140/4340 alliage.
Dimensions physiques: Ouverture d'alimentation jusqu'à 1 500 mm; total installed height varies by model (environ. 6m 9m); total operating weight from 250t 600t+.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 40°C à +50°C; dustsealed construction meets IP66 standards; suitable for highaltitude installations.

6. SCÉNARIOS D'APPLICATION

Expansion d’une mine de cuivre à grande échelle

Défi: A planned plant expansion required a primary crusher capable of sustaining >8,000 t/h on highly abrasive porphyry ore while fitting within tight space constraints of an existing pit layout.
Solution: Installation of a single Premium Gyratory Crusher with a compact "spiderless" design profile.
Résultats: A atteint un débit soutenu de 8,400 t/h with product P80 consistently below required spec. Liner life exceeded projections by 15%, contributing to a calculated payback period under three years versus alternative solutions.

HighProduction Granite Quarry

Défi: Frequent weekend liner changes were creating production bottlenecks. Unpredictable bearing temperatures led to two unscheduled stoppages in one year.
Solution: Implementation of a midrange Premium Gyratory Crusher featuring the TopService Concept and Intelligent Control System.
Résultats:Liner change time reduced from three shifts to one shift (8 heures). The monitoring system provided early warning on lube system health, preventing a potential bearing failure. Annual availability increased to 96.8%.

7. CONSIDÉRATIONS COMMERCIALES

Premium Gyratory Crushers are offered in three primary tiers based on size and duty:
1. Série robuste: For megamines (>100k tpd), featuring maximum redundancy components. Pricing reflects custom engineering.
2. Série Performances: For midtolarge scale mines and major quarries (20k100k tpd). Offers balanced capital/operating cost efficiency.
3. Configured Series: Preengineered models for specific aggregate duties (<15k tpd), offering shorter lead times.

Fonctionnalités facultatives & Forfaits:

Advanced Wear Monitoring System (radarbased)
Automated Setting Adjustment Package
Extended Warranty on drivetrain components (up to an additional two years)
Onsite commissioning supervision & programmes de formation des opérateurs

Service Agreements: Tailored plans are available covering scheduled inspections, preventive maintenance kits, parts discounts (up to15%),et des délais de réponse d'urgence garantis.

Options de financement: Flexible commercial structures include capital lease agreements,turnkey project financing,and rentaltoown programs,directly supporting your CAPEX planning cycles.

8.FAQ

T1:What level of site preparation is required comparedto other primary crushers?
UN:The foundation load specifications are comparableto other gyratory crushers of similar capacity.The TopService design often reduces overhead crane requirements,sometimes simplifying support structure design.

T2:What is the expected operational lifespanof the main structural components?
UN:The base,cadres,and mainshaft housing are engineeredfor a minimumdesign lifeof30years under normal operating conditions when maintained per our guidelines.This is validatedby FEAand historical datafrom earliergeneration units stillin operation after40+years.

Q3.How doesyour intelligent control system integratewith our existing plant DCS/SCADA?
UN:The crusher's control system communicatesvia standard industrial protocols(OPC UA.Modbus TCP/IP).Our engineers will workwith your teamto define the data pointsfor integrationensuring key performance metricsare visibleon your central dashboards without requiring proprietary softwareon your end

Q4.What arethe typical lead timesfor major wear parts like concavesand mantles?
UN:Leveraging global warehousingstrategieswe maintaintarget stock levelsfor critical wear partson our most common models.Aimto ship standard profile linerswithin46weeksfrom order confirmation.Emergency expedite optionsare available

Q5.Do you offerperformance guarantees?
A Yes we provideguaranteesfor rated capacitypower consumptionunder defined feed conditionsand mechanical availabilitysubjectto terms outlinedin our commercial agreement Theseare backedby decadesof field applicationdata