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 Common challenges with outdated or underperforming primary crushers include:

Excessive Downtime for Maintenance: Frequent liner changes and unexpected mechanical failures can halt your entire operation, costing thousands per hour in lost production.
High Operational Costs: Rising energy consumption per ton of processed material and the laborintensive nature of routine servicing directly impact your bottom line.
Inconsistent Feed Handling & Throughput: Bridging, uneven feed distribution, and inability to handle variable ore hardness lead to suboptimal capacity and product size distribution.
Premature Wear Part Failure: Improper crushing chamber design leads to accelerated abrasion on mantles and concaves, driving up your costperton for consumables.

Is your current primary crusher delivering the reliable throughput and predictable operating cost required in today's market? The solution lies in selecting a gyratory crusher engineered to address these exact pain points.

2. PRODUCT OVERVIEW: GYRATORY CRUSHER

A gyratory crusher is a stationary compressive crushing unit central to hightonnage mining and aggregate operations. It is designed for firststage, primary crushing of runofmine ore or blasted quarry rock into a size suitable for conveyor transport and secondary processing.

Operational Workflow:
1. Feed Intake: Large dump trucks or loaders deposit material into the topmounted feed hopper.
2. Crushing Action: The central shaft, fitted with a mantle, gyrates within a stationary concave liner. The eccentric motion creates a progressive compressive crushing action.
3. Product Discharge: Crushed material falls by gravity through the narrowing gap at the bottom of the chamber (the closedside setting) onto a discharge conveyor.

Application Scope: Ideal for very highcapacity applications (typically >1,000 tph) requiring continuous operation on hard, abrasive materials like granite, iron ore, and copper ore.

Key Limitations: Requires a stable, reinforced concrete foundation. Higher initial capital cost compared to large jaw crushers. Not suitable for portable plants or lowtonnage operations.

3. CORE FEATURES

Patented Concave Profile | Technical Basis: Optimized nip angle & crushing chamber geometry | Operational Benefit: Promotes interparticle crushing for finer initial product size & reduces slabby output | ROI Impact: Reduces load on downstream circuits by up to 15%, lowering overall system energy cost.

Integrated Intelligent Control System | Technical Basis: Realtime pressure & position sensors with PLC automation | Operational Benefit: Automatically compensates for liner wear & adjusts for optimal power draw | ROI Impact: Maintains consistent throughput & product size, maximizing yield over full liner life.

TopService Design | Technical Basis: Simplified maintenance access from above the crusher | Operational Benefit: Enables safe, rapid mantle changeouts without personnel entering the pit | ROI Impact: Reduces planned maintenance downtime by up to 30% versus traditional designs.

Hydroset® Tramp Release & Setting Adjustment | Technical Basis: Hydraulic cylinders support the main shaft | Operational Benefit: Allows remote adjustment of CSS for product control & automatically releases tramp iron | ROI Impact: Protects against costly damage events; enables process adjustments in minutes vs. hours.

Lube System with Filtration & Monitoring | Technical Basis: Dualcircuit oil circulation with temperature control | Operational Benefit: Ensures consistent bearing lubrication under high load; extends component life | ROI Impact: Prevents catastrophic bearing failure; field data shows a 40% increase in mean time between failures (MTBF).

HeavyDuty Spider & Mainframe Casting | Technical Basis: Highstrength alloy steel with computervalidated design | Operational Benefit: Provides structural integrity to withstand decades of highload cyclic stress | ROI Impact: Eliminates risk of frame fatigue failure; ensures longterm asset integrity over a 30+ year lifespan.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | Our Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | 92 94% | 96%+ (documented) | +35% |
| Energy Efficiency (kWh/tonne) Baseline = Hard Granite| 0.8 1.0 kWh/t| 0.65 0.75 kWh/t| 18% |
| Liner Life (Million Tonnes Processed) Varies by Material| Sitespecific; often inconsistent| Extended by patented profile & alloy| +1525% |
| Mean Time To Repair (MTTR Mantle Change)| 24 36 hours| <18 hours| 33% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2,000 to over 10,000 tonnes per hour (tph), depending on model and feed material.
Motor Power Requirement: Typically from 450 kW up to 1,200 kW (600 1,600 HP), supplied at either medium voltage (e.g., 6.6kV) or low voltage.
Feed Opening: Gape sizes from 1,000 mm to 1,500 mm standard.
Material Specifications: Mainframe constructed from normalized steel castings; concaves and mantles available in premium manganese steel alloys or composite metal matrix options.
Physical Dimensions / Footprint: Varies by model; example model requires ~7m x ~7m foundation area excluding feed hopper.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C with appropriate lubrication systems and housing options.

6. APPLICATION SCENARIOS

LargeScale Copper Mine Expansion

Challenge A major South American operation needed to increase plant throughput by 25%. Their existing primary circuit was unreliable, causing frequent bottlenecks and unpredictable maintenance shutdowns.
Solution Installation of two new heavyduty gyratory crushers with intelligent control systems as the cornerstone of their expansion project.
Results Achieved sustained throughput of over 6 ,500 tph each . Plant availability increased by 4 .2 % , meeting expansion targets while reducing specific energy consumption by 0 .15 kWh/t .

HighAbrasion Aggregate Quarry

Challenge A North American granite quarry faced unsustainable costs due to premature wear part failure every 6 –8 weeks , alongside high energy bills .
Solution Replaced an older crusher with a modern gyratory unit featuring our advanced concave profile and optional metal matrix liners .
Results Liner life extended to an average of 14 weeks . Energy consumption per ton dropped by 19 % . The resulting lower costperton secured a key longterm supply contract .

7. COMMERCIAL CONSIDERATIONS

Our gyratory crushers are offered in structured pricing tiers based on size capacity and feature sets:

Standard Duty Series: For consistent , nonabrasive feeds . Includes core reliability features .
Heavy Duty Series ( Recommended for most mining applications ) : Includes all features listed in Section 3 , with enhanced wear packages .
Extreme Duty Series: For maximum abrasion resistance , includes premium alloys , advanced monitoring sensors , and extended warranty .

Optional features include dust suppression seals , automated lubrication systems , and advanced predictive maintenance sensor packages .

We offer comprehensive service agreements covering planned maintenance , parts supply at preferential rates , and 24 /7 remote technical support . Financing options including leasetoown structures and projectbased capital expenditure plans are available through our partners .

8.FAQ

Q What are the foundation requirements for installing this equipment ?
A Detailed geotechnical specifications are provided . Generally it requires a significant mass of reinforced concrete ; our engineering team supplies full foundation drawings and load data .

Q How does this equipment integrate with our existing PLC / SCADA system ?
A The intelligent control system uses standard industrial communication protocols( e.g., Modbus TCP/IP , OPC UA ) allowing seamless data integration into your plantwide control room .

Q What is the typical delivery lead time ?
A Lead times vary by model specification but generally range from 9 –14 months exworks due to heavy casting requirements . We maintain critical spare parts inventory regionally .

Q Can you provide assistance during commissioning ?
A Yes we include supervised commissioning as standard along with comprehensive operator training programs conducted at your site .

Q What financing options are available ?
A We work with several equipment finance specialists offering operating leases capital leases or tailored purchase plans typically ranging from 3 –7 years .

Q How do you guarantee performance ?
A Performance guarantees for capacity power drawand product sizingare contractually established based on agreed feed material characteristicsand site conditions

Q Are wear parts readily available ?
A We maintaina global networkof certified parts warehouses ensuring availability Critical wear partslike mantleand concave kitsare often stocked regionallyfor rapid dispatch