White Label Gyratory Crusher Brochure
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 ?? Les principaux défis dans les opérations de concasseur giratoire comprennent souvent:
Temps d'arrêt imprévus: L'usure prématurée des composants critiques tels que les manteaux et les contre-batteurs entraîne une défaillance, causing costly, arrêts de production imprévus.
Complexité de maintenance élevée: Traditional designs require extensive labor hours for routine inspections and liner changes, keeping your skilled technicians occupied instead of on proactive tasks.
Gradation du produit incohérente: Worn or poorly configured crushing chambers yield offspec product, creating bottlenecks for downstream processes and reducing plant throughput.
Consommation d'énergie excessive: Inefficient crushing action and highfriction designs result in disproportionate power draw per ton of material processed.
What if your primary crusher could deliver higher throughput with greater reliability, while reducing both your maintenance burden and cost per ton? The solution requires a design focused on durability, facilité d'entretien, et l'efficacité des processus.
2. APERÇU DU PRODUIT
The White Label Gyratory Crusher is a heavyduty, primary compression crusher engineered for the first stage of reducing runofmine ore or quarry rock. Il est conçu pour un tonnage élevé, continuous operation in fixedplant applications.
Flux de travail opérationnel:
1. Alimentation: Matière première de grande taille (généralement jusqu'à 1,5 m de taille) is delivered via dump trucks or a primary feeder into the topmounted feed hopper.
2. Écrasement: The central gyrating mantle eccentrically compresses material against the stationary concave, fracturing rock through progressive cycles of compression.
3. Décharge: Crushed product gravitates downward through the narrowing chamber until it reaches the desired size and exits through the discharge opening at the bottom.
Champ d'application: Idéal pour les grandes capacités (2,000 10,000+ tph) mining of metal ores (cuivre, fer, or) and largescale aggregate quarries requiring consistent, sortie grossière.
Limites: Ne convient pas aux opérations de faible tonnage (<500 tph), abrasive recycling materials (par ex., béton avec barres d'armature), or applications requiring frequent relocation.
3. CARACTÉRISTIQUES PRINCIPALES
Conception concave brevetée | Base technique: Segmenté, reversible alloy steel liners | Avantage opérationnel: Prolonge la durée de vie jusqu'à 30% and allows for rotation of wear parts to utilize full profile | Impact sur le retour sur investissement: Reduces liner inventory costs and frequency of changeouts, réduire le coût par tonne
Contrôle de chambre intelligent intégré | Base technique: Realtime hydraulic adjustment and monitoring of the main shaft position | Avantage opérationnel: Enables operators to optimize product size and crusher load without stopping operation | Impact sur le retour sur investissement: Maintains target gradation for downstream efficiency; empêche les dommages causés par la surcharge
Conception de services supérieurs | Base technique: All maintenance points accessible from above via a central service platform | Avantage opérationnel: Enables safe removal of the mantle and concaves without dismantling the lower frame or feed hopper | Impact sur le retour sur investissement: Réduit d’environ le temps d’arrêt prévu pour le changement de revêtement 40%
Système de libération des tramp Hydroset® | Base technique: Hydraulically supported main shaft with automated pressure sensing | Avantage opérationnel: Automatically lifts the mantle to release tramp metal or uncrushable material, then resumes prior setting | Impact sur le retour sur investissement: Eliminates damage from uncrushables; prevents major mechanical failure and associated repair costs
Système d'entraînement à haute efficacité | Base technique: Direct Vbelt drive with highinertia flywheels and lowfriction bearings | Avantage opérationnel: Provides smooth power transmission with reduced mechanical losses under fluctuating loads | Impact sur le retour sur investissement: Les données de terrain montrent un 58% réduction de la consommation énergétique spécifique (kWh/tonne) compared to legacy geardriven systems
Condition Monitoring Portals | Base technique: Hardened access points with integrated sensor ports for oil analysis, vibration, et la température | Avantage opérationnel: Facilitates predictive maintenance by allowing easy sampling and data collection during operation | Impact sur le retour sur investissement: Shifts maintenance strategy from reactive to predictive, maximizing component life
4. AVANTAGES CONCURRENTIELS
| Mesure de performances | Moyenne standard de l’industrie | White Label Gyratory Solution Documented Performance | Avantage (% Amélioration) |
| : | : | : | : |
| Temps de changement de doublure (Majeur) | 24 36 heures
for similar size class
| <16 heures
via topservice design
| ~40 % plus rapide |
| Consommation d'énergie spécifique
(kWh per metric ton) | Varie selon le matériau; Référence = X kWh/t | X 0.08X kWh/t
via optimized drive & chambre
| 58% réduction |
| Disponibilité annuelle
(Programmé & Non programmé) | 92 94% | >96%
per fleet telemetry data
| >2 points de pourcentage |
| Temps moyen entre les pannes (MTBF)
for Major Components | ~8 000 heures | >10,500 heures
based on bearing & shaft data
| >30% augmenter |
5. SPÉCIFICATIONS TECHNIQUES
Plage de capacité: Configurable à partir de 2,000 à plus 12,000 tonnes métriques par heure (tph), en fonction du choix du modèle et du matériau d'alimentation.
Puissance du moteur: Lecteurs standards de 450 kW à 1,200 kW (600 HP – 1,600 HP). Configurations personnalisées disponibles.
Ouverture d'alimentation: Tailles d'ouverture de 1,050 mm (42») à 1,500 mm (60»).
Cadre principal & Concaves: Fabriqué à partir de tôle d'acier à haute résistance; concaves available in multiple alloy grades (Mn14Cr2 to Mn22Cr3) for optimal wear life vs. coût.
Plage de réglage de décharge: Réglable hydrauliquement de 125 mm à 250 mm (5” – 10”) selon modèle.
Plage de température de fonctionnement: Conçu pour des conditions ambiantes de 40°C à +50°C (40°F à +122°F). Optional lube oil heating/cooling packages available.
Étanchéité à la poussière: Multistage labyrinth seals with positivepressure air purge system as standard.
6. SCÉNARIOS D'APPLICATION
Expansion de la mine de cuivre – Contrainte de débit
Défi: Une exploitation majeure de cuivre nécessaire pour augmenter le débit de l'usine de 20% but was constrained by their existing primary crushing circuit’s capacity limit of ~4,800 tph and frequent concaverelated downtime.
Solution: Installation of a single White Label Gyratory Crusher (60” gape model) with highcapacity concaves and smart chamber control.
Résultats: Sustained throughput increased to an average of >5,800 tph. Topservice design reduced annual planned maintenance hours by ~200 hours. The project met its expansion throughput target within six months of commissioning.
Granite Aggregate Quarry – Product Quality & Coût
Défi: An aggregate producer faced inconsistent product cubicity from their older gyratory crusher leading to poor asphalt mix quality. They also experienced high energy costs per ton crushed.
Solution: Replacement with a midrange White Label Gyratory Crusher featuring an optimized chamber profile for aggregate shaping.
Résultats: Product flakiness index improved by over 15%, meeting premium specification requirements. The new drive system contributed to a documented annual energy saving exceeding $65k based on local power rates.
7. CONSIDÉRATIONS COMMERCIALES
White Label Gyratory Crushers are offered in three primary tiers based on size class:
1. Niveau de performances: For capacities up to ~4，500 tph， includes core features like TopService Design， Hydroset System，and standard monitoring portals。
2 Niveau Haute Capacité: For operations up to ~8，000 tph， adds Smart Chamber Control as standard， enhanced alloy liners，and upgraded bearing packages。
3 Niveau UltraDuty: Pour un débit maximal (>8，000 tph)， includes full predictive sensor suites， premium metallurgy throughout，et configurations de décharge personnalisées。
Les fonctionnalités optionnelles incluent des systèmes avancés de filtration de lubrification， automated wear measurement probes，and remote telematics integration。
Les options de financement comprennent l'achat de capital， longterm leasetoown agreements（3660 months），and certified refurbished units with full warranty。 Comprehensive service packages are available covering scheduled maintenance parts kits（PM Kits），onsite technical support during major services，and guaranteed emergency parts delivery。
FAQ
T1： Is this equipment compatible with our existing secondary crushing circuit？
UN： Oui。 Our engineering team can review your current flow sheet specifications。 The hydraulic adjustment system allows precise control over discharge settings（CSS）to ensure optimal feed gradation for your cone crushers or downstream processes。
T2： What is the expected operational impact during installation？
UN： Installation typically requires a prepared concrete foundation。 Nous fournissons des dessins de fondation détaillés。 From delivery of major components到commissioning typically requires an eighttotwelveweek site schedule depending on civil work scope。 We offer supervised installation services。
T3： How does financing work？
UN： We work with several industrial equipment finance partners。 Typical structures require an initial down payment followed by fixed monthly payments。 Lease structures may offer potential tax benefits； we recommend consulting your financial advisor。
T4： What training is provided？
UN： We provide comprehensive operator training covering normal startup/shutdown procedures daily checks troubleshooting basics。 Maintenance team training covers liner change procedures lubrication system management use of condition monitoring tools。
Q5： What are typical lead times？
UN： Lead times vary based on model tier customization。 For standard models lead time ranges from six months（Performance Tier）to ten months（UltraDuty Tier）。 We maintain critical spare parts inventory at regional hubs。
Q6： Can you guarantee performance metrics like throughput？
UN： We provide performance projections based on standardized laboratory testing results using representative samples you supply。 Final performance depends on sitespecific factors including feed characteristics fragmentation haul truck scheduling which are outside our direct control。
Q7： What is included in the warranty？
UN： Our base warranty covers defects in materials workmanship under normal use service periods ranging twelve months from commissioning date twentyfour months total from shipment date whichever occurs first。 Wear parts consumables like liners are covered under separate terms