1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit's profitability? For plant managers and engineering contractors, the primary crushing stage is a critical bottleneck where inefficiencies cascade through the entire processing line. Common challenges with outdated or undersized gyratory crushers include:
Excessive Downtime for Maintenance: Frequent liner changes and unexpected mechanical failures can halt your entire operation, costing tens of thousands per hour in lost production.
Unscheduled Stoppages from Tramp Iron: Inadequate protection systems lead to damage from uncrushable material, resulting in costly repairs and extended downtime.
Inconsistent Throughput & Product Size: Worn or poorly designed crushing chambers fail to maintain target product gradation, overloading downstream screens and mills, reducing overall plant efficiency.
High Operational & Energy Costs: Inefficient crushing action and high friction components drive up power consumption per ton of material processed.

Is your primary crusher a source of reliability, or a recurring capital project? The right gyratory crusher solution should address these challenges directly, transforming your primary stage from a cost center into a model of predictable, lowcostperton performance.

2. PRODUCT OVERVIEW: GYRATORY CRUSHER

A gyratory crusher is a stationary compressive crushing machine central to hightonnage mining and aggregate operations. It reduces large runofmine rock (up to 1.5m in size) to a conveyable product, typically between 150250mm, for secondary processing. Its core function is continuous, highcapacity primary size reduction.

Operational Workflow:
1. Feed Intake: Material is fed into the top of the crusher via dump trucks, loaders, or a feed hopper with a vibrating grizzly feeder.
2. Compressive Crushing: The central mantle gyrates within a stationary concave liner. Rock is nipped and crushed by the progressive compressive action as it moves down the chamber.
3. Discharge: Crushed material exits through the discharge opening at the bottom (the open side setting), where it is conveyed to the next stage.

Application Scope & Limitations:
Scope: Ideal for very highcapacity applications (>1,000 tph), handling abrasive hard rock (granite, basalt, iron ore), and sticky feeds. The standard for largescale mining and highvolume aggregate quarries.
Limitations: Higher initial capital cost compared to large jaw crushers. Requires a substantial foundation and elevated installation for discharge clearance. Not suitable for portable plants or lowtonnage operations (<500 tph).

3. CORE FEATURES

Patented Concave Design | Technical Basis: Segmented, alloysteel liners with optimized nip angles | Operational Benefit: Produces more consistent product gradation with fewer fines; extends liner life up to 30% | ROI Impact: Reduces liner inventory costs and changeout frequency, lowering cost per ton

Integrated Automatic Setting Regulation (ASR) | Technical Basis: Hydraulic adjustment system with realtime position sensors | Operational Benefit: Allows operators to adjust CSS remotely during operation to maintain product spec; enables automatic unblocking | ROI Impact: Maximizes yield of inspec product; eliminates manual adjustment downtime

Robust Spider & Top Shell Assembly | Technical Basis: Forged alloy steel construction with precision machining | Operational Benefit: Provides exceptional stability under shock loads; maintains precise alignment for consistent crushing action | ROI Impact: Minimizes risk of catastrophic failure; ensures longterm reliability and asset protection

HighCapacity Lube System with Filtration | Technical Basis: Dualpump circulation system with temperature control and particle filtration | Operational Benefit: Ensures critical bearings operate within optimal temperature range; removes contaminant particles | ROI Impact: Extends bearing service life by years; prevents lubricationrelated breakdowns

Tramp Iron Relief System | Technical Basis: Hydraulic cylinders support the mainshaft; pressuresensitive release mechanism | Operational Benefit: Automatically opens the crusher to pass uncrushable material, then returns to original setting | ROI Impact: Prevents damage to mainshaft and headnut; avoids days of downtime associated with major repairs

StateoftheArt Control System (IC50C) | Technical Basis: PLCbased automation integrated with plant DCS via standard protocols (Modbus TCP/IP) | Operational Benefit: Provides realtime monitoring of power draw, pressure, temperature, and CSS; enables predictive maintenance alerts | ROI Impact: Allows proactive maintenance planning; optimizes performance through datadriven decisions

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Operational Uptime) | 9294% | 9698% documented field average| +4% (+400+ hours annually) |
| Specific Energy Consumption (kWh/t) Varies by material hardness| Baseline = 100%| Field data shows consistent reduction of 812%| 10% average improvement |
| Liner ChangeOut Time (Major Set) Varies by model size| Baseline = 100%| Engineered tooling & procedures reduce time by ~25%| 25% faster turnaround |
| Throughput Capacity (tph) for equivalent feed opening| Baseline = 100%| Optimized chamber design increases capacity by 510%| +7% average increase |

Supporting field performance reports available upon request.

5. TECHNICAL SPECIFICATIONS

Capacity Range: Modeldependent from 2,000 to over 10,000 metric tons per hour (tph).
Feed Opening: Ranges from 800mm to 1,500mm.
Motor Power: Typically between 300 kW to over 800 kW (400 HP 1,000+ HP), depending on model and application.
Total Weight: From approximately 150 tonnes up to 500+ tonnes for largest models.
Material Specifications: Main frame and concaves manufactured from highstrength cast steel or forged alloys; Mantles are premium manganese steel.
Physical Dimensions: Significant footprint requiring engineered concrete foundation. Height varies greatly by model but often exceeds 5 meters from base to feed opening.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C with appropriate lubrication systems.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: An existing mine required a primary crusher capable of processing an additional 5 million tpy of highly abrasive porphyry ore without increasing maintenance crew size or compromising plant availability targets below 98%.
Solution: Installation of a heavyduty 60inch gyratory crusher featuring our advanced concave system and automated setting regulation.
Results: Achieved sustained throughput of 4,500 tph while extending concave service life by 28%. Annual maintenance hours were reduced by 15%, meeting availability targets.

HighProduction Granite Quarry

Challenge: A quarry producing railroad ballast faced inconsistent product yield due to worn chamber profiles in their old crusher, leading to excessive recirculating load and screen overloads.
Solution: Replacement with a new generation gyratory crusher designed specifically for aggregate shaping.
Results: The proportion of inspec cubical product increased by 18%. Power consumption per ton dropped by 9%, and downstream screen wear rates decreased noticeably due to better feed gradation.

7. COMMERCIAL CONSIDERATIONS

Our gyratory crushers are offered across several tiers:
Standard Duty Series: For consistent feeds in aggregate applications.
Heavy Duty/Extra Heavy Duty Series: For severeservice mining applications with abrasive ores.

Optional features include:
Automated lubrication system health monitoring
Wear part condition monitoring sensors
Extended warranty packages on major components
Customized service access platforms

We offer comprehensive service agreements covering scheduled inspections, parts supply programs at fixed rates per ton crushed ("crushing cost per ton" contracts), and emergency support plans.

Flexible financing options are available through our partners including equipment leasing structures tailored for multiyear mine plans or traditional capital purchase arrangements.

8. FAQ

Q1: Can this gyratory crusher be integrated into my existing PLC/SCADA control system?
Yes. The standard control system uses industrial communication protocols like Modbus TCP/IP or OPC UA for straightforward integration into most plantwide distributed control systems.

Q2: What is the typical installation timeline from delivery commissioning?
For a greenfield site with foundation prepared in advance,the mechanical erection typically requires 46 weeks,followed by electrical tieinand commissioning.The total project duration is highly dependent on sitespecific civil works.

Q3:What levelof operational trainingis provided?
We provide comprehensive trainingfor your maintenanceand operations teams covering safe operation routine inspections basic troubleshootingand liner changeout procedures Documentation includes detailed manualsand taskspecific videos

Q4:What arethe key factorsin determiningthe correctmodel size?
The selectionis basedon your maximumfeed sizerequired hourly throughput(tph)the typeand abrasivenessofthe rockandthe desiredproductsize Computerizedselectionprogramsusingour proprietarycrushing simulationsoftwareare usedto ensureoptimal sizing

Q5:Whatisthe expectedservice lifeof themain structuralcomponents?
The mainframe topshell assemblyandspiderare designedfor thelifespanofthe mineor quarryoften exceeding yearswith propermaintenance Criticalwear parts(concavesmantle)have servicelivesdependenton feedmaterialtypically rangingfrom monthsfor veryabrasiveapplicationsto yearsin lesssevereservice