1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang semakin meningkat dan ketersediaan yang tidak dapat diramalkan menghakis keuntungan litar penghancur utama anda? Key challenges in gyratory crusher operations directly impact your bottom line:
Masa Henti Tidak Berjadual: Bearing failures or mainshaft issues can halt your entire processing line for days, menelan belanja ratusan ribu dalam pengeluaran yang hilang.
Kos Penyelenggaraan Tinggi: Kerap, laborintensive liner changes and component wear consume both maintenance budgets and valuable operating hours.
Inconsistent Throughput & Saiz produk: Turun naik dalam bahan suapan atau haus dari semasa ke semasa membawa kepada produk offspec, creating bottlenecks and reducing downstream efficiency.
Penggunaan Tenaga Berlebihan: Older or inefficient designs draw more power per ton processed, a fixed cost that significantly impacts operating margins.

Bagaimanakah anda mencapai daya pengeluaran yang lebih tinggi dengan kebolehpercayaan yang lebih tinggi sambil mengawal jumlah kos pemilikan? The solution requires a crusher engineered not just for peak performance, tetapi untuk berterusan, predictable operation under the most demanding conditions.

2. GAMBARAN KESELURUHAN PRODUK

The Custom Gyratory Crusher is a heavyduty, primary crushing machine designed for hightonnage, continuous operation in largescale mining and aggregate production. It performs compressive crushing via a gyrating mantle within a concave hopper.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Runofmine (ROM) ore or large quarry rock is directly dumped into the top of the crusher’s deep, nonchoking concave.
2. Penghancuran Mampatan: The eccentrically gyrating mantle repeatedly advances and recedes from the concave liners, applying massive compressive force to reduce material size.
3. Kawalan Tetapan Pelepasan: The crushed product exits through the adjustable bottom setting (ABS), dengan saiz ditentukan oleh tetapan sisi tertutup (CSS) between the mantle and concave at their lowest point.
4. Pelepasan & Pengangkutan: Sized material is discharged onto a primary conveyor for transport to the next stage of processing.

Skop Permohonan: Ideal for primary crushing of abrasive hard rock (bijih besi, bijih tembaga, granit), hightonnage aggregate production, and heap leach applications requiring coarse product. Not recommended for lowtonnage operations, soft or nonabrasive materials only, or sites with severe space constraints where a jaw crusher may be more appropriate.

3. CIRI TERAS

Patented QS™ Quill Shaft System | Asas Teknikal: Isolated eccentric motion with hydrostatic lubrication | Faedah Operasi: Eliminates metaltometal contact in the eccentric assembly, drastically reducing wear and risk of catastrophic failure | Kesan ROI: Data medan menunjukkan sehingga 40% longer service intervals for the eccentric system and a documented 60% pengurangan masa henti tidak berjadual berkaitan.

INTEGRAL™ Concave & Mantle Liner System | Asas Teknikal: Interlocking alloy segments with optimized chamber geometry | Faedah Operasi: Provides more consistent product gradation throughout liner life and reduces changeout time by up to 30% compared to traditional designs | Kesan ROI: Lower liner cost per ton crushed and increased crusher availability for production.

SMARTSENSE™ Bearing Monitoring | Asas Teknikal: Integrated vibration, suhu, and pressure sensors on critical bearings | Faedah Operasi: Your maintenance team receives realtime health data and predictive alerts, enabling conditionbased maintenance planning | Kesan ROI: Mencegah kegagalan galas yang tidak dijangka, protects against secondary damage to shafts and housings.

HYDROSET® PLUS Chamber Clearing & Pelarasan | Asas Teknikal: Dualfunction hydraulic ram system for setting adjustment and automated chamber clearing | Faedah Operasi: Operators can adjust CSS under load or clear a stalled cavity remotely in minutes from the control room | Kesan ROI: Memaksimumkan masa operasi; eliminates hours of manual clearing efforts and associated safety risks.

HEAVYDUTY Spiral Bevel Gear & Pinion | Asas Teknikal: Forged alloy steel gears with computeroptimized tooth profile | Faedah Operasi: Transmits high torque smoothly with minimal noise and vibration, even under uneven loading conditions | Kesan ROI: Industry testing demonstrates a typical service life extension of 25% over standard gear sets under comparable duty cycles.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Purata Piawaian Industri | Custom Gyratory Crusher Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Adanya (Masa Jalan yang Dijadualkan) | 9294% | 96.5%+ | +35% |
| Masa Pertukaran Pelapik (Jam) | 2436 jam | 1620 jam | ~40% Lebih Pantas |
| Penggunaan tenaga (kWj/t) Baseline Ore| 0.8 1.2 kWj/t| 0.65 0.9 kWj/t| Hingga 20% Lebih Cekap |
| Masa Min Antara Kegagalan (MTBF) Eccentric System| ~12,000 hrs| >18,000 jam| +50% Kebolehpercayaan |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Model boleh dikonfigurasikan daripada 2,000 tph sampai habis 10,000 tph.
Pembukaan suapan: daripada 1,070 mm (42”) hingga 1,520 mm (60”) bergantung kepada model.
Keperluan Kuasa Motor: Biasanya 375 kW kepada 750 kw (500 HP ke 1000 HP+), dibekalkan di 6.6 kV or as required.
Jumlah Berat: Berjulat dari kira-kira 150 tan hingga lebih 400 tan untuk konfigurasi terbesar.
Spesifikasi Bahan Utama:
Bingkai utama & Shell atas: Highstrength fabricated steel with stressrelieving treatment.
Mainshaft: Forged from highalloy nickelchromiummolybdenum steel.
Cekung & Pelapik Mantel: Aloi keluli mangan (14%18% Mn), optional chromewhite iron or composite alloys for specific abrasion/corrosion applications.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 40°C hingga +50°C. Dust seals rated for harsh environments; pilihan sistem pemanasan/penyejukan tersedia.

6. SENARIO APLIKASI

Pengembangan Lombong Tembaga Berskala Besar

Cabaran: A planned expansion required a primary crusher capable of handling an additional 8 million tonnes per annum of highly abrasive porphyry ore without increasing footprint or headcount disproportionately.
Penyelesaian: Installation of one Custom Gyratory Crusher with INTEGRAL™ liners configured for coarse crushing ahead of SAG mills.
Keputusan: Mencapai daya pengeluaran yang berterusan sebanyak 4,500 tph at a consistent P80 of 150mm. Hayat pelapik meningkat secara purata sebanyak 15%, contributing to a calculated total cost per tonne reduction of approximately $0.12 across the crushing circuit.

Kuari Granit Pengeluaran Tinggi

Cabaran: Frequent downtime due to tramp metal events causing damage and lengthy cavity clearing procedures was limiting annual output targets.
Penyelesaian: Implementation of our gyratory crusher equipped with the HYDROSET® PLUS system and SMARTSENSE™ monitoring.
Keputusan: Cavity clearing events reduced from an average operational delay of 8 jam ke bawah 45 minutes per incident. Annual plant availability increased by over 300 jam (12+ hari), directly translating to an additional ~450k tonnes crushed per year within existing shifts.

7 PERTIMBANGAN KOMERSIL

Equipment pricing is structured into three primary tiers based on size/capacity (CGC50 Series, CGC60 Series, CGC72 Series) with base configurations including core drive system controls motor starter lubrication unit

Ciri pilihan termasuk:
Advanced automation packages remote diagnostic telemetry special alloy liner packages dust suppression ring

Pakej perkhidmatan ditawarkan secara berasingan:
Gangsa (Waranti Asas) Perak (Planned Inspection & Parts Discount) emas (FullService Contract including scheduled labor parts predictive monitoring)

Financing options are available through our partners including capital lease operating lease project financing terms typically structured over years

Soalan Lazim

Apakah garis masa pemasangan biasa?
From delivery onsite mechanical erection electrical connection commissioning full operation typically requires weeks depending on foundation readiness site support

How does this crusher integrate with my existing control system?
The crushers PLC is designed for interoperability providing standard communication protocols Modbus TCP/IP Profibus We supply full interface documentation

Can you provide wear part cost guarantees?
Yes we offer guaranteed maximum wear part cost per tonne contracts based on your specific feed material analysis providing predictable longterm budgeting

Apakah syarat pembayaran anda?
Standard commercial terms involve progress payments tied key milestones delivery acceptance Final payment due upon successful completion performance run

Adakah anda menawarkan latihan pengendali?
Comprehensive training is included covering safe operation routine maintenance troubleshooting conducted both at commissioning at your facility