1. PAINPOINT DRIVEN OPENING

Are your gold processing operations constrained by inefficient primary crushing? The initial size reduction stage sets the tone for your entire recovery circuit, and suboptimal performance here creates cascading losses. Common challenges include:
Excessive Downtime: Frequent liner changes and unplanned maintenance in harsh gold ore environments halt your milling circuit, costing thousands per hour in lost production.
Inconsistent Feed Size: Poorly fragmented, slabby output from primary crushers leads to bridging in bins, reduced throughput in SAG mills, and ultimately, lower gold recovery rates.
High Operational Costs: Premature wear on crusher components due to abrasive quartz and sulfide minerals drives up your costperton metric for consumables like mantles, concaves, and jaw plates.
Energy Inefficiency: Older crushing technology often requires more power to achieve the required reduction ratio, directly impacting your site’s energy budget.

Is your primary crushing circuit a bottleneck or a catalyst for profitability? The right heavyduty equipment is not an expense but a strategic investment in plant stability and metal recovery.

2. PRODUCT OVERVIEW

This content details our range of Stationary Primary Gyratory Crushers engineered specifically for hightonnage gold ore processing plants. These machines are designed for the first stage of comminution, accepting runofmine (ROM) feed directly from the mine.

Operational Workflow:
1. ROM gold ore (up to 1500mm) is fed into the crusher’s deep chamber via dump trucks or a primary feeder.
2. The eccentrically rotating mantle continuously compresses ore against the stationary concave, achieving progressive crushing.
3. Crushed material discharges via gravity through the bottom setting, producing a consistent product size typically between 150mm to 250mm for feed to secondary crushing or SAG mills.

Application Scope: Ideal for largescale gold mining operations with annual throughput exceeding 5 million tonnes. Best suited for hard, abrasive ores (e.g., quartz vein hosted).
Limitations: Not recommended for smallscale operations (<500,000 tpa) due to high capital cost and footprint. Requires stable concrete foundations and significant overhead clearance for maintenance.

3. CORE FEATURES

Patented Spider Design | Technical Basis: Multiarm forged steel construction with top shell sealing | Operational Benefit: Distributes load evenly, prevents dust ingress at the feed point, and allows for safer mantle changing | ROI Impact: Reduces scheduled maintenance windows by up to 30%, extending major service intervals.

Intelligent Chamber Profiling | Technical Basis: CADoptimized concave and mantle geometry based on ore characterization data | Operational Benefit: Maximizes nip angle throughout the chamber for efficient compression crushing and consistent product gradation | ROI Impact: Improves overall circuit throughput by 515% through optimal feed size for downstream processes.

Automated Setting Regulation System (ASRi) | Technical Basis: Realtime hydraulic adjustment of the Closed Side Setting (CSS) with continuous monitoring | Operational Benefit: Compensates for wear automatically, maintaining product size without manual intervention; provides overload protection | ROI Impact: Ensures stable mill feed quality, optimizing recovery; protects against tramp metal damage events.

Lube System with Condition Monitoring | Technical Basis: Highvolume filtration with temperature and pressure sensors feeding into plant SCADA | Operational Benefit: Ensures constant bearing lubrication under peak load; provides early failure warning diagnostics | ROI Impact: Prevents catastrophic bearing failures—the leading cause of extended crusher downtime—saving weeks of potential lost production.

Wear Component Metallurgy | Technical Basis: Austenitic Manganese Steel alloys with optional chrome or ceramic matrix composites for critical zones | Operational Benefit: Withstands extreme abrasion from silica; predictable wear life allows for precise maintenance planning | ROI Impact: Lowers costperton for wear parts by up to 25% compared to standard alloys through extended service life.

Integrated Maintenance Platform | Technical Basis: Builtin gantry points and safeaccess platforms around the top shell | Operational Benefit: Enables faster, safer liner inspections and changes without requiring additional mobile equipment | ROI Impact: Reduces labor hours per maintenance task by an average of 20%, lowering direct operating costs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Jaw Crusher / Older Gyratory) | Our Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | 8590% (excluding liner changes) |> 94% (with ASRi & predictive lube system) |> +5% operational time |
| Throughput Capacity (tph) per kW| Lower ratio due to inefficient stroke/cycle| Optimized chamber design yields higher volume per cycle| +1015% efficiency |
| Wear Life of Concaves (Abrasive Ore)| ~800k 1.2M tonnes| Proprietary alloy achieves >1.5M tonnes| +25% extended life |
| Product Size Consistency (Variance)| Higher F80 variance affecting SAG mill stability| ASRi maintains CSS within ±5mm tolerance| +50% consistency |
| Energy Consumption per Tonne| Baseline reference kWh/t| Optimized kinematics reduce specific energy demand| 7% reduction |

5. TECHNICAL SPECIFICATIONS

Capacity Range: 2,000 – 10,000+ tonnes per hour (dependent on model & ore characteristics).
Feed Opening: Ranging from 1,000mm to 1,500mm gape.
Motor Power: 300 kW – 800 kW electric drive motors.
Total Weight: From ~150 tonnes to over 400 tonnes (crusher only).
Material Specifications: Main frame of fabricated steel; Shaft from forged alloy steel; Standard concaves in Mn18Cr2 alloy.
Physical Dimensions: Significant footprint; requires purposebuilt reinforced concrete foundation. Specific LxWxH provided per model.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dusttight construction suitable for arid or highaltitude installations common in gold mining regions.

6. APPLICATION SCENARIOS

LargeScale Open Pit Mine (West Africa) | Challenge: A Tier1 operator faced escalating downtime from jaw crusher fatigue failures under increased ROM hardness, bottlenecking a 12 Mtpa CIP plant. Unpredictable product size also caused SAG mill inefficiencies.| Solution: Replacement with a heavyduty primary gyratory crusher featuring ASRi automation and advanced chamber profiling tailored to the ore body.| Results: Achieved sustained throughput of >2,500 tph at target CSS. Mill feed consistency improved by 40%, contributing to a documented +1.5% improvement in overall gold recovery within six months due to stable grinding conditions.

HighAltitude Underground Mine (South America) Challenge:| Transporting large volumes of lowgrade ore required maximized primary reduction underground to minimize hoisting costs.| Solution:| Installation of a compact but highcapacity gyratory crusher directly at the underground coarse ore bin station.| Results:| Primary crushed product allowed more efficient skip loading and hoisting cycles.Tonnage hoisted increased by ~18%. Energy consumption per tonne hoisted decreased significantly due to better volumetric efficiency.

7. COMMERCIAL CONSIDERATIONS

Our primary gyratory crushers are capital investments structured around longterm operational savings.

Pricing Tiers: Configured based on size/capacity:
EntryClass: For midscale operations (~24 Mtpa).
ProductionClass: For major mines (~48 Mtpa).
EliteClass: For megaprojects (>8 Mtpa), featuring full smart sensor integration.
Optional Features: Advanced condition monitoring packages; specific wear material upgrades (e.g., ceramic liners); custom discharge conveyor interfaces; remote operational support connectivity.
Service Packages: We offer tiered plans from basic preventive maintenance support up to fullsite crushing circuit performance guarantees with shared risk/reward structures based on uptime and costpertonne targets.
Financing Options: Available through partner institutions including equipment leasing models that convert capex to opex,and project financing linked to mine production milestones.

8. FAQ

Q1: Is this equipment compatible with our existing secondary cone crushers and conveying system?
Yes.Engineering assessments ensure proper interface design.The discharge product size is engineered specifically as optimal feed for your downstream circuit.We provide full integration studies as part of the presales technical review.

Q2:What is the typical installation timeline,and what site preparation is required?
From delivery,the mechanical installation typically requires68 weeks.This necessitates prepared foundations based on our detailed civil drawings.Field assembly is supervised by our commissioning engineers.Site preparation is a critical path item managed collaboratively with your project team

Q3:What training do you providefor our operationsand maintenance crews?
We supply comprehensive training modules covering normal operation,troubleshooting,and planned maintenance procedures.This includes both classroom theoryand handson sessions during commissioning.We also leave behind detailed digital manuals accessible via tablet

Q4:What arethe commercial terms regarding warrantyand spare parts availability?
The standard warranty covers manufacturing defectsfor12 monthsfrom commissioning.We maintain global warehousing networksfor critical spareswith guaranteed availability levels.Service level agreements(SLAs)forspare parts delivery can be negotiated

Q5:Canyou quantifythe expected impactonour overall processingplant recovery rate?
Whilethe crusher itself does not extract goldfield data consistently shows that providinga consistent optimally sizedfeedtoyour grinding mills reduces F80 variabilityThis directly improves grindingcircuit stabilityand liberationoften resultingin measurable recovery gainsas documentedin provided case studies