1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? Key challenges in primary crushing often include:

Unscheduled Downtime: Bearing failures or mainshaft issues can halt your entire processing line, costing tens of thousands per hour in lost production.
High Maintenance Costs: Frequent, laborintensive liner changes and component wear directly impact your maintenance budget and manpower allocation.
Inconsistent Throughput: Fluctuations in feed size or hardness can cause chokefed conditions or poor cavity utilization, failing to meet designed tonnage targets.
Product Quality Issues: Poorly controlled discharge settings lead to offspec product size distribution, placing undue stress on downstream screening and secondary crushing stages.

How do you achieve consistent, hightonnage reduction of runofmine material while controlling total cost of ownership? The solution lies in selecting a gyratory crusher engineered not just for capacity, but for reliability and operational efficiency.

2. PRODUCT OVERVIEW: GYRATORY CRUSHER

A gyratory crusher is a stationary primary compression crusher, central to largescale mining and aggregate operations. It utilizes a gyrating mantle within a concave hopper to progressively reduce large feed material (typically up to 1.5m in size) to a manageable product for conveyor transport to downstream processes.

Operational Workflow:
1. Feed Intake: Runofmine ore or quarry rock is dumped directly from haul trucks into the topmounted feed hopper.
2. Progressive Compression: The central mantle gyrates eccentrically within the fixed concave liners, continuously compressing and fracturing material as it travels down the crushing chamber.
3. Discharge: Crushed material exits through the discharge opening at the bottom, with size primarily controlled by the vertical position of the mantle.

Application Scope & Limitations:
Scope: Ideal for highcapacity (1,000 10,000+ tph) primary crushing applications with abrasive, hard ores (e.g., copper, iron, gold) or hard rock aggregates. Suited for continuous operation with direct truck or shovel feeding.
Limitations: Higher capital cost than comparable jaw crushers. Requires a stable, reinforced concrete foundation. Not suitable for lowtonnage operations or highly plastic/sticky materials without modification.

3. CORE FEATURES

Patented Concave & Mantle Profiles | Technical Basis: Computermodeled crushing kinematics | Operational Benefit: Optimized nip angle and chamber geometry ensure efficient reduction with lower power draw per tonne crushed. | ROI Impact: Field data shows up to 8% reduction in specific energy consumption versus older profile designs.

Integrated Main Shaft & Eccentric Assembly | Technical Basis: Forged alloy steel shaft with precisionmachined eccentric | Operational Benefit: Provides exceptional torsional strength and fatigue resistance for processing tramp metal and uncrushables with reduced risk of catastrophic failure. | ROI Impact: Extends major service intervals; documented instances show >30% longer service life in highshock load applications.

Automated Liner Thickness Monitoring System | Technical Basis: Ultrasonic sensor array integrated into the frame | Operational Benefit: Continuously tracks liner wear without manual entry, allowing for predictive maintenance scheduling and optimal crusher setting adjustments. | ROI Impact: Maximizes liner utilization by 1015% and prevents unplanned stops due to sudden wearthrough events.

Hydroset™ Tramp Release & Setting Adjustment | Technical Basis: Hydraulic piston supporting the main shaft | Operational Benefit: Enables remote adjustment of the crusher discharge setting in minutes for product control and provides instant tramp iron release to clear blockages without downtime. | ROI Impact: Reduces clearing time from hours to minutes; allows rapid product size changes to meet shifting plant demands.

Labyrinth Seal & Positive Pressure System | Technical Basis: Multistage sealing with filtered air blower | Operational Benefit: Effectively excludes dust and slurry from critical lubrication systems, dramatically reducing bearing contamination. | ROI Impact: Industry testing demonstrates a direct correlation with extending bearing life by over 40% in abrasive environments.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gyratory Crusher Solution | Documented Advantage |
| : | : | : | : |
| Availability (Operating Time) | 92 94% | >96% annual availability target| +24% improvement |
| Liner ChangeOut Duration (Major) | 48 72 hours| 26 months with sealing system| >40% improvement |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable models from 1,500 to over 12,000 tonnes per hour (tph).
Power Requirements: Drive motor ratings from 300 kW up to 1 MW+, dependent on model size and duty.
Material Specifications: Highstrength fabricated steel frame; Martensitic steel or manganese alloy concave/mantle liners; Forged alloy steel main shaft.
Physical Dimensions (Example Model): Total height ~68m; Feed opening up to 1500mm; Discharge setting range 150250mm.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C; dustsealed components rated for IP65 protection.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge: A tierone copper operation needed to increase plant throughput by 25%. Their existing primary circuit was bottlenecked by an aging crusher with low availability and high energy costs per tonne.
Solution: Installation of a new highcapacity gyratory crusher featuring optimized kinematics and an automated lubrication system.
Results: Achieved sustained throughput at design capacity of 6,500 tph with a measured 7% reduction in specific energy consumption. Firstyear availability recorded at 96.7%.

Granite Aggregate Quarry Upgrade

Challenge: A quarry producing railroad ballast faced inconsistent product gradation and excessive liner wear costs due to highly abrasive feed.
Solution: Implementation of a gyratory crusher with specialized chamber profiles and premiumgrade abrasionresistant liners.
Results: Product cubicity improved by over 15%, meeting strict rail specifications consistently. Liner life increased by an average of two weeks per set under identical feed conditions.

7. COMMERCIAL CONSIDERATIONS

Equipment pricing is structured according to size/capacity tier:
Standard Duty Range: For aggregate and mediumhard ore applications.
Heavy Duty Range: For hardrock mining and highabrasion environments.
Super Duty Range: For megamine projects requiring maximum throughput and durability.

Optional features include advanced condition monitoring packages (vibration/temperature), semiautomatic liner handling systems, and custom discharge conveyor interfaces.

Comprehensive service packages are available:
Planned Maintenance Agreements: Fixedcost coverage for scheduled inspections and parts.
Performance Contracts: Guaranteed availability targets with shared risk/reward terms.
Financing options include capital lease agreements tailored to project cash flow cycles.

8.FAQ

Q1. Is this gyratory crusher compatible with our existing plant control system?
Yes—the unit's PLCbased control system is designed for industrystandard communication protocols (e.g., Modbus TCP/IP). It can be integrated into your central SCADA system for remote monitoring/control after standard interface configuration

Q2. What is the typical installation timeline from delivery commissioning?
For a greenfield site installation including foundation work typically requires between four six months depending on civil engineering complexity Brownfield replacements can be executed faster often within three months using preengineered retrofit plans

Q3. How does this equipment impact our overall operating cost structure?
The primary impact is shifting cost elements While capital investment is significant operational costs are reduced through lower energy consumption extended component lifecycles reduced labor hours maintenance These factors typically yield improved total cost ownership over seven ten year period

Q4. What commercial terms are available beyond standard purchase orders?
We offer structured finance solutions including equipment leasing long term rental purchase options Additionally performance based contracts link portion payment agreed operational metrics like availability throughput

Q5. What training provided our operations maintenance teams?
Commissioning includes comprehensive onsite training covering safe operation routine maintenance procedures troubleshooting diagnostics We also provide detailed technical manuals access online knowledge portal updated service bulletins