1. PAINPOINT DRIVEN OPENING

Is your limestone mining operation struggling with consistent product quality and unpredictable yield? The challenges of variable seam hardness, abrasive silica content, and the need for precise sizing directly impact your profitability. Are you experiencing:
Excessive Downtime: Frequent wear part replacement and unplanned maintenance on primary crushers halting your entire processing line.
High Operational Costs: Rising energy consumption per ton of crushed material and escalating costs for consumable wear parts like mantles and concaves.
Inconsistent Product Gradation: Offspec material leading to product rejection, reduced sale value, or reprocessing costs.
Dust & Noise Compliance: Increasing regulatory pressure and community relations concerns around dust emission and noise levels from the primary crushing stage.

The selection of your primary crushing solution dictates the efficiency of your entire downstream process. How do you achieve higher throughput with lower costperton while maintaining strict product specifications?

2. PRODUCT OVERVIEW: GYRATORY CRUSHER FOR LIMESTONE MINING

This product line comprises heavyduty primary gyratory crushers engineered specifically for hightonnage limestone mining applications. Designed as the first critical stage in size reduction, it transforms blasted quarry run into a consistent, manageable feed for secondary crushing circuits.

Operational Workflow:
1. Feed Intake: Dump trucks or loaders deposit large (up to 1.5m) blasted limestone rock into the crusher’s deep, nonchoking feed hopper.
2. Compressive Crushing: The central mantle gyrates within the concave, applying intense compressive force to break rock against itself (interparticle crushing).
3. Discharge Setting Control: The crushed material exits through the adjustable bottom setting, determining the primary product size (typically 150250mm).
4. Direct Feed to Conveyor: The crushed product is discharged onto a main conveyor belt for transport to the next stage of processing.

Application Scope & Limitations:
Scope: Ideal for highcapacity (2,000+ TPH) limestone quarries with abrasive feed material. Suited for stationary primary crushing stations.
Limitations: Not designed for mobile inpit crushing or for processing highly ductile or claycontaminated materials without prescreening.

3. CORE FEATURES

Patented Concave Profile | Technical Basis: Optimized crushing chamber geometry | Operational Benefit: Delivers a consistent, predictable product gradation curve with fewer fines generation | ROI Impact: Reduces secondary circuit load and improves overall plant yield by an estimated 37%.

Integrated Automatic Setting Regulation | Technical Basis: Hydraulic adjustment and overload protection system | Operational Benefit: Allows operators to adjust CSS remotely for product changes and automatically reverts after tramp iron events | ROI Impact: Minimizes unplanned stops; field data shows a 40% reduction in downtime related to clearing jammed cavities.

Lube System with Condition Monitoring | Technical Basis: Closedloop filtration with realtime temperature and pressure sensors | Operational Benefit: Ensures constant bearing protection against abrasive dust; provides predictive maintenance alerts | ROI Impact: Extends major bearing service intervals by up to 50%, preventing catastrophic failure.

Wear Part Metallurgy | Technical Basis: Austenitic Manganese Steel alloy with patented heattreatment process | Operational Benefit: Concaves and mantles develop a workhardened surface that withstands limestone's high abrasiveness | ROI Impact: Increases wear life by 2030% over standard alloys, lowering costperton for consumables.

Dust Suppression Integration Manifold | Technical Basis: Preengineered ports for dry fog or spray nozzle systems at key dust generation points | Operational Benefit: Contains dust at source during loading and crushing without saturating material | ROI Impact: Simplifies compliance with environmental regulations and reduces site water usage.

Spiderless Design (on Select Models) | Technical Basis: Eliminates the traditional spider bridge at the top of the crusher | Operational Benefit: Allows faster, safer mantle changes; provides unobstructed feed opening for larger rock | ROI Impact: Reduces scheduled maintenance time by up to 30%, directly increasing annual available operating hours.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Cone Crusher as Primary) | Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Throughput Capacity (TPH Hard Limestone) | Up to 1,500 TPH | 2,000 10,000+ TPH | +33% to +300% at scale |
| Operational Availability (%)| ~85% (more frequent liner changes)| ~92% (longer wear life & faster service)| +7 percentage points |
| Energy Efficiency (kWh/tonne)| Varies widely; higher at full capacity| Lower specific energy consumption at high tonnage| Up to 15% improvement |
| Feed Size Acceptance Ratio| Limited by feed opening diameter| Larger relative feed size capability| Accepts rock up to 30% larger |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 2,000 to over 12,000 metric tons per hour (based on model and feed conditions).
Motor Power: Heavyduty electric motors from 300 kW up to 800 kW.
Feed Opening: Ranges from 1,000 mm to 1,500 mm.
Discharge Setting Range: Adjustable from 125 mm to 300 mm CSS (Closed Side Setting).
Main Frame Construction: Fabricated steel plate with reinforced stress zones; corrosionresistant interior liners.
Weight & Dimensions: Approximate installed weight from 150 tonnes; requires reinforced concrete foundation.
Ambient Operating Range: Designed for operation from 20°C to +45°C ambient temperature with appropriate lube oil specifications.

6. APPLICATION SCENARIOS

HighVolume Aggregate Producer Challenge:

A major aggregate supplier faced inconsistent feed from multiple quarry benches causing cyclical overloading of their primary cone crushers and excessive wear.

Solution:

Implementation of a single largecapacity gyratory crusher as the unified primary node.

Results:

Throughput stabilized at 3,200 TPH; wear part life increased by 22%; plant availability reached 91%.

Cement Plant Raw Material Extraction Challenge:

A cement plant's inquarry crushing system struggled with high silica content limestone, leading to concave failures every 45 months and costly kiln feed chemistry fluctuations.

Solution:

Installation of a gyratory crusher with specialized abrasionresistant concaves and integrated prescreening bypass.

Results:

Wear life extended to over 14 months; product gradation consistency improved kiln feed homogeneity; total cost of ownership decreased by an estimated 18%.

7. COMMERCIAL CONSIDERATIONS

Our gyratory crushers are offered in three core tiers based on capacity and feature sets:

1.
Standard Duty Tier: For operations up to 3,500 TPH. Includes core features like standard metallurgy concaves and basic automation.
2
.Heavy Duty Tier (Recommended): For operations from 3,500 – 7 ,000 TPH . Includes premium wear metallurgy , integrated setting regulation ,and advanced condition monitoring .
3
.Ultra HighCapacity Tier : For megaquarries exceeding 7 ,000 TPH . Includes spiderless design options , custom chamber profiles ,and full plant interface control .

Optional features include advanced predictive analytics software packages , automated lubrication systems ,and turnkey dust suppression modules . We offer comprehensive service agreements covering planned maintenance , parts forecasting ,and remote technical support . Flexible financing solutions including leasetoown models are available through our commercial partners .

8.FAQ

Q:What is the lead time for a new gyratory crusher?
A :Lead times vary by model complexity but typically range from 9 – 14 months from order placement .We maintain a stock programfor key components .

Q :Can this equipment integratewith our existing secondarycrushing circuit?
A :Yes .Our engineering team will reviewyour current flow sheetto ensure properfeed sizematchingand conveyor compatibility .

Q:What arethe power requirementscomparedto multipleprimary cone crushers?
A :While total connected power maybe similar,a singlegyratory often operatesat ahigherload factorwith betteroverall energyefficiencyper toncrushed .

Q:Doyou offerwear partguaranteesor performancebasedcontracts?
A :We offertonnageguaranteedwear partpackageswherecostpertonis fixedforagivenmaterial specification .

Q:Whatisthe typicalinstallationand commissioning timeline?
A :With preparedfoundations,crusher erectiontakesapproximately4–6 weeks.Full commissioningincluding integrationtakesanadditional2–3 weeks .

Q:Arethere financingoptionsavailableforcapitalpurchase?
A Yes.We workwithseveralindustrial equipmentfinanciersto providetailored solutionsincludingoperating leases,fixedterm loans,and rentalpurchaseagreements