1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Managing a premium iron ore crushing plant demands consistent throughput and cost control. Les défis opérationnels courants comprennent:
Temps d'arrêt imprévus: Frequent liner changes and mechanical failures in primary crushers halt your entire processing line, coûtant des milliers de dollars par heure en perte de production.
Taille du produit incohérente: Fluctuations in feed size and hardness lead to poor fragmentation, overloading downstream circuits like grinding mills, which dramatically increases energy costs.
Coûts de maintenance élevés: Abrasive iron ore rapidly wears crusher components, resulting in excessive spending on replacement parts and significant labor hours for upkeep.
Inefficacité énergétique: Older crushing stages often operate at nonoptimal settings, consuming more power per ton of material processed than necessary.

Are you evaluating how to increase plant availability, réduire le coût par tonne, and achieve a more consistent feed for your beneficiation circuit? The foundation of this efficiency starts with your primary crushing solution.

2. APERÇU DU PRODUIT

Cette gamme de produits comprend des véhicules lourds, concasseurs giratoires primaires stationnaires conçus spécifiquement pour les tonnages élevés, abrasive iron ore applications. As a private label manufacturer, we provide equipment built to your precise operational specifications and branding requirements.

Flux de travail opérationnel:
1. Runofmine (ROM) iron ore is fed via haul trucks or apron feeder into the crusher’s deep chamber.
2. The eccentrically rotating mantle continuously compresses ore against the concave liners, achieving size reduction through progressive rockonrock crushing.
3. Crushed material discharges via gravity through the bottom setting, ready for secondary crushing or direct conveyor transport.

Champ d'application: Idéal pour les opérations minières à grande échelle avec des capacités annuelles dépassant 10 million tonnes of magnetite or hematite ores. Convient aussi bien aux nouvelles installations qu'aux mises à niveau.

Limites: Non conçu pour les opérations à faible tonnage (< 2 million tonnes annually) or for processing highly plastic or sticky materials without specific feed system modifications.

3. CARACTÉRISTIQUES PRINCIPALES

Géométrie de chambre brevetée | Base technique: Optimized nip angle and crushing stroke profile | Avantage opérationnel: Achieves targeted product size in a single pass more consistently, réduisant la charge de recirculation | Impact sur le retour sur investissement: Jusqu'à 15% higher throughput compared to conventional chambers of similar intake size

Système d'amélioration de la durée de vie du revêtement | Base technique: Automated liner condition monitoring and wear compensation technology | Avantage opérationnel: Maintains crusher setting automatically for stable output; fournit des alertes de maintenance prédictive | Impact sur le retour sur investissement: Prolonge les intervalles de doublure de 2030%, reducing downtime and part costs

Système de lubrification hybride | Base technique: Dedicated circuits for bearing lubrication and piston pressure with independent cooling | Avantage opérationnel: Ensures reliable operation under high dust load and variable ambient temperatures common in iron ore plants | Impact sur le retour sur investissement: Reduces risk of bearingrelated catastrophic failure; les données de terrain montrent un 40% amélioration du temps moyen entre pannes (MTBF) for lubrication systems

Conduite intelligente & Intégration du contrôle | Base technique: Moteur synchrone à couple élevé associé à un variateur de fréquence (VFD) contrôle | Avantage opérationnel: Permet des démarrages en douceur, power draw optimization, and adjustment of crushing speed to match ore characteristics | Impact sur le retour sur investissement: Reduces peak electrical demand by up to 35% during startup; optimizes kWh per ton consumed

Modular Concave & Mantle Assembly | Base technique: Conception de revêtement segmenté avec verrouillage mécanique | Avantage opérationnel: Enables faster liner changes using standard plant maintenance tools; reduces changeout time by up to 50% | Impact sur le retour sur investissement: Réduit les coûts de main-d'œuvre par événement de maintenance et augmente la disponibilité de l'usine

Étanchéité anti-poussière intégrée & Endiguement | Base technique: Multistage labyrinth seals combined with positivepressure air barriers | Avantage opérationnel: Effectively contains dust particles at the feed and discharge points, critical for meeting site environmental standards | Impact sur le retour sur investissement: Minimizes material loss and reduces cleanup costs, protecting downstream equipment from abrasive dust

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Moyenne) | Cette solution de concasseur giratoire | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité (Temps de fonctionnement prévu) | 92 94%| 96%+| ~34% increase |
| Débit de tonnage (tph comparable size) Ligne de base = 100%| 100%| 108 115%| Jusqu'à 15% higher |
| Durée de vie de la doublure (Millions de tonnes traitées)| Varies by ore abrasiveness| +2030%| 2030% durée de vie plus longue |
| Consommation d'énergie spécifique(kWh/t)| Ligne de base = 100%| 92 95%|58% réduction |
| Temps moyen de réparation(Major Liner Change hours)| ~48 heures| <36 heures|25+% plus rapide |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 5,000 à plus 12,000 tonnes par heure (tph), depending on model selection and feed conditions.
Exigences d'alimentation: Entraîner les moteurs de 600 kW jusqu'à 1.5 MW. Compatible with mediumvoltage supply (3.3 kV 6.6 kV). Full electrical package including VFDs and control panel is supplied.
Spécifications matérielles: Main frame constructed from highintegrity cast steel. Concave liners available in premium manganese steel alloys or optional composite metal matrix materials for extreme abrasion resistance.
Dimensions physiques: Tailles d'ouverture d'alimentation à partir de 1,200 mm à 1,500 mm. Overall installation footprint is customized per plant layout but is designed to minimize civil works requirements.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +50°C. Dust sealing effective in conditions with airborne particulate levels exceeding 50 mg/m³.

6. SCÉNARIOS D'APPLICATION

LargeScale Hematite Operation – Throughput Expansion

Défi: A major Australian mine needed to increase plant throughput by over 20% sans étendre l'empreinte de leur concasseur principal ni surcharger les convoyeurs existants.
Solution: Replacement of an older primary crusher with a highcapacity gyratory crusher featuring the Patented Chamber Geometry and Intelligent Drive system.
Résultats: A obtenu un résultat soutenu 22% increase in average hourly tonnage through the primary circuit while reducing specific energy consumption by 7%. The consistent product size reduced bottlenecks at the secondary screening stage.

Magnetite Concentrator – Reducing Downtime

Défi: A Canadian concentrator faced excessive unplanned downtime due to unpredictable liner wear in their primary crusher, causing scheduling conflicts with downstream grinding mills.
Solution: Installation of a gyratory crusher equipped with the Liner Life Enhancement System and Modular Concave Assembly.
Résultats: Liner change intervals became predictable within a ±5% window, allowing maintenance to be scheduled during planned mill stops. Total annual downtime attributed to primary crushing was reduced by approximately 180 heures.

7. CONSIDÉRATIONS COMMERCIALES

Our private label manufacturing model provides flexibility across commercial terms:

Niveaux de tarification des équipements: Based on capacity rating and material specification choices (par ex., standard contre. premium liners). Options range from core crusher supply only to full packaged stations including feeders, passerelles, and chute work.
Fonctionnalités facultatives: Capteurs avancés de surveillance d’état (vibration, température), systèmes automatisés de réglage des réglages (ASRI), specialized wear protection packages for specific ore geochemistry.
Forfaits de services: Tiered offerings include onsite supervision during commissioning; multiyear liner supply contracts with guaranteed wear rates; assistance au diagnostic à distance; and scheduled inspection services.
Options de financement: We work with international export credit agencies and equipment financing partners to offer leasetoown structures or term loans tailored to project finance requirements.

8. FAQ

1. How does this equipment integrate with our existing secondary crushing circuit?
The discharge setting is fully adjustable within its designed range to ensure optimal feed size distribution for your cone crushers or HPGRs.

2 What is the expected impact on our overall plant operating costs?
Industry data from comparable upgrades indicates a reduction in total cost per ton of crushed material between $0.15$0 .35 USD , primarily from lower energy use , extended wear part life ,and increased availability .

3 Des garanties de performance sont-elles offertes?
Oui . We provide contractual guarantees for rated capacity under defined conditions , consommation d'énergie spécifique ,and major component wear life based on your provided ore characterization data .

4 What are the lead times for delivery ?
Lead times vary based on model complexity but typically range from9to14months exworksforafullycustomizedprimarycrusher . Expedited options may be available .

5 Do you provide supportfor foundation designand installation ?
We supply comprehensive foundation loading diagramsand interface drawings . Onsite technical supervision during installationand commissioningis available as partof our service packages .

6 Canyou accommodateour company’s brandingand documentation standards ?
Asa private label manufacturer ,thisisacore service . Equipment can bebadgedwithyourbrand,and all manuals ,dessins,and control system interfacescanbe formattedto your specifications .

7 Howdoesthe intelligent drive systemhandlepowerfluctuations commonatremote mine sites ?
The integrated VFDsystem includes line reactorsand harmonic filteringto protectthe motorfromgrid disturbances .Itcanalsobe configuredfor controlled shutdownsin caseofundervoltage events topreventmechanical damage