1. PAINPOINT DRIVEN OPENING

Are you managing gold ore processing operations where throughput bottlenecks and unpredictable maintenance costs are eroding your profit margins? The primary crushing stage often dictates the efficiency of your entire plant. Common challenges with suboptimal gold ore crushing equipment include:

Excessive Downtime: Unplanned stoppages for liner changes or component failure directly reduce mill feed, costing thousands per hour in lost production.
High Abrasion Costs: Gold ores, particularly those with high quartz content, rapidly wear crusher components, leading to frequent, expensive replacements and inconsistent product sizing.
Inefficient Liberation: Inadequate or inconsistent particle size reduction from the primary stage can hinder downstream recovery in grinding and leaching circuits, leaving valuable gold locked in larger particles.
Energy Inefficiency: Older or poorly matched crushing equipment consumes excessive power per ton of ore processed, a significant and growing operational cost.

Is your current setup delivering the optimal balance of availability, wear cost per ton, and final product size for maximum gold recovery? The right primary crushing solution is not just about breaking rock; it's about securing the foundation of your plant's profitability.

2. PRODUCT OVERVIEW: PRIMARY JAW CRUSHER FOR GOLD ORE PROCESSING

This heavyduty jaw crusher is engineered as the first line of size reduction in hard rock gold mining operations. It is designed to accept runofmine (ROM) gold ore with a maximum feed size and reliably reduce it to a consistent discharge for conveyor transport to secondary crushing or stockpiling.

Operational Workflow:
1. ROM ore is fed via dump truck or loader into the vibrating grizzly feeder (VGF), which bypasses subcrusher fines.
2. Oversize material is directed into the crusher’s fixed and moving jaw plates, where compressive force fractures the rock.
3. Crushed material exits through an adjustable discharge gap, determining the product’s top size.
4. The crushed product is conveyed for further processing.

Application Scope & Limitations:
Scope: Ideal for primary crushing of hard, abrasive gold ores (e.g., quartz veins). Suitable for both stationary plants and semimobile setups.
Limitations: Not designed for wet, sticky ores without proper feeder design. Maximum feed size is constrained by the crusher’s gape dimension.

3. CORE FEATURES

HeavyDuty Frame Design | Technical Basis: Finite Element Analysis (FEA) optimized stress distribution | Operational Benefit: Eliminates frame fatigue cracking under cyclical loading from hard rock; ensures longterm structural integrity | ROI Impact: Prevents catastrophic frame failure and associated monthslong downtime, protecting capital investment

Manganese Steel Jaw Plates | Technical Basis: Workhardening alloy composition | Operational Benefit: Plate surfaces harden upon impact, increasing service life in highly abrasive quartz environments | ROI Impact: Reduces liner change frequency by 3050%, lowering parts inventory costs and increasing crusher availability

Hydraulic Toggle Adjustment System | Technical Basis: Integrated hydraulic ram for tensioning & clearing | Operational Benefit: Allows quick, safe adjustment of CSS (Closed Side Setting) for product control; enables automatic clearing of tramp metal/stalling events in minutes | ROI Impact: Minimizes nonproductive time for setting changes and blockages by up to 80% compared to manual shim systems

Large Feed Opening & Deep Crushing Chamber | Technical Basis: Optimized geometry based on nip angle principles | Operational Benefit: Accepts larger ROM feed blocks without bridging; provides longer wear life on jaw plates due to optimized motion | ROI Impact: Increases effective capacity and reduces precrushing or hammering requirements at the grizzly

Centralized Greasing System | Technical Basis: Automated lubrication points routed to a single station | Operational Benefit: Ensures critical bearings receive consistent lubrication without operator exposure to moving parts | ROI Impact: Extends bearing service life by up to 40%, preventing costly unplanned bearing failures

BoltIn Toggle Seats | Technical Basis: Modular, replaceable seat design | Operational Benefit: Worn toggle seats can be replaced without major welding or machining on the main frame | ROI Impact: Significantly reduces repair time and cost during major overhauls

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | This Jaw Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | 8590% | 9496%| +6% (Reduced downtime) |
| Wear Cost per Ton (Abrasive Ore)| $0.45 $0.60/tonne| $0.32 $0.38/tonne| ~30% Reduction |
| Energy Consumption| 0.85 1.1 kWh/tonne| 0.72 0.80 kWh/tonne| ~20% Improvement |
| CSS Adjustment Time| 24 hours (manual)| 90% Faster |

5. TECHNICAL SPECIFICATIONS

Model & Capacity: JC1500HD; Throughput range of 650 – 1,100 mtph depending on feed gradation and CSS.
Feed Opening: 59” x 78” (1500mm x 2000mm).
Power Requirements: 300 kW (400 HP) electric motor drive; standard softstart system included.
Material Specifications: Main frame fabricated from highstrength steel; jaw plates from premium grade manganese steel (1418%); shaft from forged alloy steel.
Physical Dimensions: Approx. Length: 10.5m, Width: 4.2m, Height: 4.8m (including drive base).
Environmental Operating Range: Designed for ambient temperatures from 25°C to +50°C; dust sealing standard; optional highaltitude motor configurations available.

6. APPLICATION SCENARIOS

Hard Rock Underground Mine Portal Application

Challenge A midtier underground gold mine needed a reliable primary crusher at the portal to handle lumpy ROM ore (48”) with minimal fines generation for subsequent agglomeration before heap leaching.
Solution Installation of a JC1500HD jaw crusher with an integrated heavyduty apron feeder.
Results Achieved consistent 8” product at a rate of ~800 mtph with >95% availability over the first year. Fines generation (<1/2”) was maintained below target levels at <15%, optimizing agglomeration reagent use.

HighThroughput Open Pit Mine Expansion

Challenge An expanding openpit operation faced bottlenecks in their existing threestage plant due to an undersized primary crusher requiring frequent maintenance stops.
Solution Replacement with a highercapacity JC1500HD unit equipped with hydraulic toggle and automated greasing.
Results Plant throughput increased by an average of 18%. Maintenance hours on the primary station decreased by 35%, directly attributable to reduced liner changes and automated clearing functions.

7.COMMERCIAL CONSIDERATIONS

Equipment pricing is structured around configuration:

Base Tier: Standard jaw crusher with motor drives and basic guarding.
Operational Tier (Most Common): Includes integrated motor base, hydraulic toggle adjustment system, centralized greasing, and starter panel.
Plant Integration Tier: Crusher supplied with matched vibrating grizzly feeder (VGF), walkways/platforms, chute work, and PLC control interface.

Optional features include dust suppression systems specialized liners for specific ore geologies advanced condition monitoring sensors.

Service packages range from annual inspections to comprehensive fulllifecycle support contracts including planned outage management parts supply guarantees financing options include capital purchase leasetoown agreements tailored operating leases based on tonnes crushed.

8.FAQ

Q What are my options if my gold ore has high clay content causing potential packing?
A We recommend pairing the crusher with a robust vibrating grizzly feeder VFG designed for scalping sticky material Optional hydraulic clearing prevents packingrelated stalls

Q How does this equipment integrate with my existing secondary cone crushers?
A The jaw crushers discharge setting CSS is easily adjusted via the hydraulic system to produce an optimal feed gradation for your specific secondary stage maximizing overall circuit efficiency

Q What is the expected lead time on critical wear parts like jaw plates?
A Based on our global distribution network standard manganese jaw plates are stocked regionally with guaranteed shipment within 72 hours under our premium service plan

Q Are there financing structures that align payment with my production output?
A Yes we offer tonnebased lease agreements where your monthly payment is partially indexed to actual tonnes processed sharing operational risk during rampup or lowergrade periods

Q What training is provided for our maintenance crew?
A Commissioning includes comprehensive handson training covering daily inspections CSS adjustment tramp clearing procedures and planned liner change protocols