1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit's profitability? Plant managers and engineering contractors consistently face critical challenges with their primary gyratory crushers: excessive liner wear leading to high consumable costs, unscheduled downtime for mantle changes that halts the entire process flow, and inconsistent feed opening performance causing bottlenecks in downstream operations. Furthermore, the high energy consumption of an inefficient crusher directly impacts your bottom line, while the complexity of maintenance requires specialized labor and extends repair windows. How do you increase throughput while controlling maintenance costs? Can you achieve greater reliability without compromising on feed size or reduction ratio? The solution requires equipment engineered not just for performance, but for total operational cost management.

2. PRODUCT OVERVIEW

The [Manufacturer Name] Primary Gyratory Crusher is a heavyduty compression crusher engineered for the first stage of size reduction in hightonnage mining and aggregate operations. Its core function is to accept runofmine or quarry feed material and reduce it to a conveyable size for further processing.

Operational Workflow:
1. Feed Intake: Large feed material is directed into the crushing chamber via a feed hopper and spider.
2. Compressive Crushing: The mantle gyrates within the concave liners, applying compressive force to break particles against themselves and the chamber walls.
3. ​Progressive Reduction: Material travels down the chamber, undergoing repeated compression until it reaches the required discharge size.
4. Discharge: Crushed product exits through the discharge opening at the bottom of the crusher, dictated by the closedside setting (CSS).

Application Scope & Limitations:
Scope: Ideal for hightonnage (typically >1,000 tph) hard rock mining (copper, iron ore), largescale aggregate quarries, and industrial mineral processing. Designed for continuous, 24/7 operation.
Limitations: Not suitable for lowtonnage operations due to high capital cost. Less effective on highly abrasive materials without specific liner metallurgy. Requires a stable, reinforced concrete foundation and significant headroom for installation and maintenance.

3. CORE FEATURES

Patented Concave Design | Technical Basis: Segmented, reversible liners with optimized profile | Operational Benefit: Increases service life by up to 30%, allows for rotation of segments to utilize full wear life evenly | ROI Impact: Reduces liner inventory costs and frequency of changeouts, lowering costperton

Integrated Automatic Setting Regulation | Technical Basis: Hydraulic piston coupled with position sensors | Operational Benefit: Enables realtime CSS adjustment under load for consistent product grading; facilitates automatic overload protection (tramp release) | ROI Impact: Maintains optimal throughput and protects downstream equipment from damage, maximizing plant uptime

Superior Spider & Bushing Design | Technical Basis: Largediameter alloy steel bushings with centralized lubrication | Operational Benefit: Provides exceptional stability to the main shaft under shock loads, minimizing vibration and wear on critical components | ROI Impact: Extends major component life, reduces risk of catastrophic failure requiring extended downtime

StateMonitored Lube System | Technical Basis: Filtration unit with flow, temperature, and pressure sensors tied to plant control system | Operational Benefit: Ensures optimal bearing lubrication; provides early warning diagnostics for potential issues before they cause damage | ROI Impact: Prevents costly bearing failures; enables predictive maintenance scheduling versus reactive repairs

TopService Design Philosophy | Technical Basis: All routine service tasks accessible from above via removable arms/spider | Operational Benefit: Eliminates the need for personnel to work beneath suspended components; simplifies liner change procedures significantly | ROI Impact: Reduces safety risks, shortens planned maintenance downtime by up to 50%, lowering labor hours

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | [Manufacturer Name] Gyratory Crusher Solution | Advantage (% improvement) |
| : | : | : | : |
| Liner ChangeOut Time (Major) | 48 72 hours | 24 36 hours | ~50% faster |
| Specific Energy Consumption (kWh/t) | Varies by ore; baseline = X kWh/t| Field data shows reductions of X15% kWh/t| Up to 15% more efficient |
| Availability (Scheduled Maintenance) | ~9294% availability target| Achieves >96% availability in documented cases| >2 percentage point increase |
| Total Cost of Ownership (5year estimate)| Based on standard liner life/energy use| Lower consumable cost + energy savings = reduced TCO| Estimated 1018% lower TCO |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Series includes models from 4265 to 60113 (feed opening x mantle diameter in inches). Capacities range from 2,000 mtph to over 10,000 mtph, dependent on ore characteristics and closedside setting.
Power Requirements: Installed motor power from 300 kW up to 1 MW. Drive system includes heavyduty AC motor,Vbelt drive or direct drive options,and gear & pinion set.
Material Specifications: Main frame constructed from highstrength,welded steel plate. Concave liners available in manganese steel alloys, with optional chrome white iron or composite materials for highly abrasive applications.
Physical Dimensions & Weight: Total installed height ranges from ~6m to >9m. Total operating weight can exceed 400 tonnes, requiring detailed foundation engineering.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust seals protect internal mechanisms; systems can be configured for dusty or wet environments.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: A tierone copper operation needed to debottleneck its primary circuit to meet increased throughput targets of 25%. The existing gyratory crusher required frequent liner changes that caused production delays.
Solution: Implementation of a [Manufacturer Name] 6089 Gyratory Crusher featuring the patented concave design and topservice layout.
Results: Achieved a sustained throughput increase of 28%. Liner service life improved by 22%, reducing annual consumable costs by an estimated $180k. Planned maintenance time was reduced by 40%.

HighAbrasion Aggregate Quarry

Challenge: A granite quarry faced prohibitively high wear costs and inconsistent product gradation due to variable feed hardness in its primary crushing stage.
Solution: Installation of a specially configured gyratory crusher with composite liners in key wear zones and integrated automatic setting regulation.
Results: Wear part costs per ton were reduced by 18%. The automatic regulation maintained product gradation within a ±5mm specification over 95% of operating time, improving downstream screening efficiency.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Capital pricing is modeldependent based on size/capacity tier (e.g., MediumCapacity Range vs SuperDuty Range). Pricing includes crusher assembly,motor,and drive guards.Base installation engineering support is typically included.
Optional Features / Packages:
Advanced Automation Package (includes remote monitoring/adjustment)
Special Wear Material Package (premium alloys)
Modular Maintenance Tool Kit
Extended Environmental Protection Package
Service Packages: Offered as annual contracts covering scheduled inspections,lube system servicing,and priority technical support.Tiered levels provide varying degrees of parts coverage/discounts.
Financing Options Available through manufacturer's financial services division include traditional capital lease,taxoriented lease structures,and projectbased financing solutions tailored for large capital expenditures.

8\. FAQ

1\. Q How does this gyratory crusher integrate with our existing plant control system?
A The crusher's PLCbased control system is designed with standard communication protocols (e.g., Modbus TCP/IP). It can be integrated as a subsystem within your wider SCADA/DCS network,facilitating centralized monitoring.

2\. Q What is the expected impact on our overall plant energy consumption?
A Field data shows that due to optimized kinematics and efficient drive design,the specific energy consumption per ton crushed can be lower than older designs.An energy audit during project planning can provide sitespecific projections.

3\. Q Are there financing options that align with our project's cash flow requirements?
A Yes.Financing structures are available that can match payments with project rampup phases or offer seasonal payment plans aligned with production cycles.Detailed proposals require review of project specifics.

4\. Q What level of technical support is provided during commissioning?
A Standard commercial terms include supervised commissioning conducted by factorytrained engineers.This encompasses initial startup,system calibration,and operator training over a defined period.

5\. Q Can this equipment handle our specific ore type which has both high hardness and abrasiveness?
A Our engineering team conducts application reviews using provided ore characteristics.We specify liner metallurgy profiles accordingly.Options like hybrid composite liners are available specifically for such challenging conditions.

6\. Q What are typical lead times from order placement to delivery?
A Lead times vary by model complexity.Current standard lead times range from X months.For critical path projects,"fasttrack" manufacturing slots may be available subjectto inquiry.

7\. Q How does your warranty structure address major components like the main shaft or eccentric assembly?
A The standard warranty covers defects in materials/workmanship.A separate,bonded warranty extensionfor major structural componentsis often available as an option providing defined coverage terms