1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your primary crushing circuit's profitability? For plant managers and engineering contractors, the primary crushing stage is a critical bottleneck where failures have cascading, costly consequences. Common challenges include:

Unscheduled Downtime: Bearing failures or unexpected wear part changes can halt your entire processing line, costing tens of thousands per hour in lost production.
High Maintenance Costs: Frequent, laborintensive liner changes and component overhauls consume both budget and valuable maintenance crew hours.
Inconsistent Throughput & Product Size: Fluctuations in feed material or equipment limitations lead to poor fragmentation, placing undue stress on downstream crushers and mills, reducing their efficiency and lifespan.
Excessive Energy Consumption: An inefficiently operating primary crusher is one of the single largest power draws on site, directly impacting your costperton metric.

Is your operation equipped with a primary crusher designed to mitigate these risks through robust engineering and intelligent design? A reliable gyratory crusher is not merely an expense but a strategic investment in plantwide stability and throughput.

2. PRODUCT OVERVIEW: GYRATORY CRUSHER

A gyratory crusher is a largescale, stationary primary crushing machine central to hard rock mining and hightonnage aggregate operations. It functions by utilizing a gyrating mantle within a concave hopper to compress and fragment large feed material (often exceeding 1 meter in size) into a smaller, consistent product for secondary processing.

Operational Workflow:
1. Feed Intake: Runofmine (ROM) ore or large quarry rock is directed into the top of the crusher's deep, rugged concave.
2. Compressive Crushing: The eccentrically driven mantle gyrates within the stationary concave, repeatedly compressing the material against the chamber walls.
3. Progressive Reduction: Material is crushed continuously as it moves down through the chamber due to gravity and the crushing action.
4. Discharge: The nowreduced material exits through the discharge opening at the bottom, with size controlled by the closedside setting (CSS).

Application Scope & Limitations:
Scope: Ideal for highcapacity (1,000+ TPH) primary crushing applications involving abrasive ores (copper, gold, iron) and hard rock aggregates. Excels in handling slabby material and provides continuous crushing action.
Limitations: Higher initial capital cost compared to large jaw crushers. Requires a substantial foundation and elevated installation for discharge conveyor access. Not suitable for portable plants or lowtonnage operations.

3. CORE FEATURES

Patented Concave Design | Technical Basis: Segmented, alloyoptimized liners with enhanced chamber geometry | Operational Benefit: Extends liner service life by up to 30%, promotes better nip angle for more efficient crushing | ROI Impact: Reduces liner inventory costs and changeout frequency, lowering cost per ton crushed.

Integrated Intelligent Control System | Technical Basis: Realtime monitoring of power draw, pressure, and CSS with automated adjustment protocols | Operational Benefit: Prevents overload conditions, optimizes throughput dynamically, provides predictive maintenance alerts | ROI Impact: Maximizes energy efficiency by 515% and prevents catastrophic damage from tramp metal or feed surges.

Spiderless Top Shell Design | Technical Basis: Eliminates traditional spider arms through a reinforced singlepiece top shell | Operational Benefit: Removes a major wear point, simplifies maintenance access for mantle changeouts by up to 50% faster | ROI Impact: Directly reduces planned maintenance downtime hours, increasing annual available operating time.

HighCapacity Main Shaft & Bearing Assembly | Technical Basis: Forged alloy steel shaft supported by heavyduty radial and thrust bearings with advanced lubrication circuits | Operational Benefit: Provides unmatched durability under peak load conditions; bearing temperature monitoring ensures reliability | ROI Impact: Eliminates unplanned failures related to the core drivetrain—the most costly source of extended downtime.

Automated Wear Part Measurement | Technical Basis: Laserbased cavity profiling system integrated into control platform | Operational Benefit: Provides accurate, operatorsafe measurement of mantle and concave wear without manual entry | ROI Impact: Enables optimal liner change scheduling based on actual wear data, preventing premature changes or runtofailure risks.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Liner Life (Abrasive Ore) | ~6 Months Average Life Cycle| 8+ Months Demonstrated Life Cycle| +33% Improvement |
| Energy Efficiency (kWh/ton) Baseline = 100%| ~0.85 1.1 kWh/tonne| Optimized range of 0.75 0.95 kWh/tonne| Up to 15% Reduction |
| Mantle ChangeOut Time (Crew Hours)| 24 36 Hours Typical Downtime| 25% Faster |
| Annual Availability Target (Excluding Planned Stops)| ~92 94% Availability Goal| >96% FieldVerified Availability| +24% Uptime Increase |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Available in multiple sizes with nominal capacities from 1,200 to over 10,000 tonnes per hour, based on specific ore characteristics and closedside setting.
Power Requirements: Main drive motors from 300 kW up to 800+ kW, tailored to duty requirements; complete Ehouses available.
Material Specifications: Mantle & concaves manufactured from proprietary Manganese steel alloys; main shaft from highstrength forged steel; base frame constructed from heavyduty fabricated steel plate.
Physical Dimensions & Weight: Varies significantly by model; largest units can exceed 10 meters in height with installed weights over 500 tonnes. Foundation loading data provided for engineering.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust sealing systems are standard; optional kits available for extreme arctic or tropical environments.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: A Tier1 copper operation needed to increase primary crushed throughput by 25% without expanding their truck dump pocket or adding building footprint due to space constraints.
Solution: Implementation of a highcapacity gyratory crusher with an optimized stroke and higher motor power within an existing footprint replacement project.
Results: Achieved a sustained throughput increase of 28%. The intelligent control system managed variable ore hardness effectively, protecting downstream conveyors while meeting new tonnage targets without major structural modifications.

Granite Aggregate Quarry Modernization

Challenge: A major quarry faced excessive downtime every 912 months for complete spider arm replacement on their aging primary gyratory crusher—a process taking over two weeks.
Solution: Replacement with a modern spiderless top shell design gyratory crusher model sized for their future reserves.
Results: Eliminated spiderrelated maintenance entirely. Planned mantle changes are now completed in under two days instead of two weeks for major overhauls—a direct recovery of over ten days of production annually while reducing labor costs.

7. COMMERCIAL CONSIDERATIONS

Our gyratory crushers are offered as engineered capital solutions with clear total cost of ownership benefits.

Pricing Tiers: Configured based on size/capacity (Standard Duty, Heavy Duty, Super Heavy Duty) with corresponding structural reinforcements and component ratings.
Optional Features & Upgrades: Key options include advanced lubrication filtration systems fully automated setting adjustment cylinders remote diagnostic telemetry packages specialized liner alloys for specific abrasion/corrosion profiles
Service Packages: Comprehensive support plans are available including scheduled inspection programs guaranteed parts availability programs (e.g., nextflightout spares) dedicated technical support hotline
Financing Options: We work with international financing partners to offer flexible solutions including capital lease operating lease project financing structures tailored for mining assets

8.FAQ

Q What level of foundation engineering is required?
A These are heavy dynamic load machines Detailed geotechnical analysis is required We provide full dynamic load data specifications early in project discussions enabling your civil engineers to design an appropriate foundation

Q How does this integrate with our existing PLC/SCADA system?
A The crushers intelligent control system communicates via industrystandard protocols Modbus TCP/IP Profinet It can function as a standalone unit or be fully integrated into your plants central control room

Q What is the typical lead time from order placement commissioning?
A Lead times vary by model complexity but generally range between months This includes manufacturing testing disassembly shipping reassembly onsite supervision We provide detailed project milestone schedules upon quotation

Q Are performance guarantees offered?
A Yes we offer performance guarantees based on mutually agreed test protocols postinstallation These typically cover throughput capacity product size distribution PSD power consumption under defined feed conditions

Q What training is provided operators maintenance staff?
A We provide comprehensive onsite training covering normal operation emergency procedures routine maintenance tasks troubleshooting Training manuals video libraries are supplied as standard

Q Can you supply all auxiliary equipment conveyors dust suppression etc
A We act as main supplier can coordinate supply installation all associated auxiliary equipment through our network vetted partners providing singlepoint responsibility turnkey projects