1. PEMBUKAAN PAINPOINT DRIVEN

Are escalating maintenance costs and unplanned downtime eroding your primary crushing circuit’s profitability? Plant managers and engineering contractors face persistent operational challenges with their primary crushing stations, termasuk:

Masa Henti Berlebihan untuk Perubahan Pelapik: Reka bentuk tradisional memerlukan masa yang panjang, laborintensive shutdowns for mantle and concave replacement, costing 2448 hours of lost production each cycle.
Pengendalian Makanan Tidak Konsisten & SurgeRelated Damage: Merapatkan, pengasingan, and direct dump surge from haul trucks lead to uneven wear, premature component failure, and cyclical stress on the entire crusher assembly.
Kos Operasi yang Tinggi & Ketidakcekapan Tenaga: Suboptimal crushing chambers and outdated drive systems fail to maximize throughput per kilowatthour, memberi kesan secara langsung kepada metrik costperton anda.
Limited Flexibility for Future Expansion: Fixedcapacity crushers cannot adapt to increased ore hardness or higher tonnage requirements without a complete capitalintensive replacement.

Is your operation equipped to reduce total cost of ownership while improving throughput reliability? The solution lies in specifying a modern, highperformance gyratory crusher from a specialized contract manufacturer.

2. GAMBARAN KESELURUHAN PRODUK: GIRATORY CRUSHER

A gyratory crusher is a primary compression crushing machine integral to largescale mining and aggregate operations. Ia mengurangkan bijih runofmine atau batu kuari dengan memampatkannya di antara pelapik cekung tetap dan mantel berkilat yang dipasang pada gelendong berayun.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Material is fed into the top of the crusher via a dump pocket or apron feeder.
2. Penghancuran mampatan: Pemasangan gelendong tengah, dengan mantel yang dipasang, girat dalam cekung pegun. Pergerakan sipi ini berulang kali memampatkan batu terhadap dinding cekung.
3. Pengurangan Progresif: Rock fragments are crushed progressively as they descend through the chamber until they reach the required discharge size.
4. Pelepasan: Crushed material exits through the discharge opening at the bottom of the crushing chamber (tetapan sisi tertutup), conveyed onward for further processing.

Skop Permohonan & Batasan:
Skop: Sesuai untuk hightonnage (1,500+ tph) primary crushing applications with abrasive or hard ores (mis., Tembaga, bijih besi, emas). Suited for stationary plants with direct dump or large feeder systems.
Batasan: Higher capital cost versus jaw crushers; requires substantial foundational support; not suitable for portable plants or lowtonnage operations (<500 tph).

3. CIRI TERAS

Reka Bentuk Cekung yang Dipatenkan | Asas Teknikal: bersegmen, alloyoptimized liners with mechanical locking | Faedah Operasi: Mengurangkan masa pertukaran pelapik sehingga 40% versus bolted designs | Kesan ROI: Lowers labor costs and increases plant availability by hundreds of production hours annually.

Intelligent Chamber Profiling | Asas Teknikal: CADoptimized chamber geometry based on feed material modeling | Faedah Operasi: Ensures consistent nipangle and even wear distribution for stable product gradation | Kesan ROI: Memanjangkan hayat pelapik dengan 1525%, reducing consumable cost per ton.

Integrated Main Shaft Position System | Asas Teknikal: Realtime hydraulic monitoring of main shaft vertical position | Faedah Operasi: Allows operators to adjust the closedside setting under load for precise product control | Kesan ROI: Maintains target product size without stopping, optimizing downstream process efficiency.

Pelinciran Hibrid & Dust Seal System | Asas Teknikal: Multistage labyrinth seals with positivepressure grease barrier | Faedah Operasi: Effectively excludes abrasive dust from bearing and lubrication systems | Kesan ROI: Mencegah kegagalan galas pramatang, extending major service intervals by thousands of operating hours.

Pemanduan Terus & Torque Limiting | Asas Teknikal: Lowspeed synchronous motor coupled with an inline torque limiter | Faedah Operasi: Eliminates Vbelt maintenance and provides controlled slip protection against tramp metal | Kesan ROI: Reduces drive system maintenance costs and prevents catastrophic overload damage.

Advanced Control System Interface | Asas Teknikal: PLCbased system with standard MODBUS/OPC protocols | Faedah Operasi: Enables seamless integration into plantwide SCADA for remote monitoring of power draw, tekanan, dan suhu | Kesan ROI: Facilitates predictive maintenance scheduling and optimizes crusher performance in realtime.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Penyelesaian Gyratory Crusher Kami | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Masa Tukar Pelapik (Major) | 3648 jam | 2230 jam | ~40% pengurangan |
| Adanya (tahunan) | 9294% | 9597%+ | ~35% peningkatan |
| Kecekapan menghancurkan (kWj/tan) Berbeza mengikut bahan. Garis asas ditetapkan setiap projek. Data medan menunjukkan pengurangan sebanyak 510% are achievable through optimized chamber design and drive efficiency. |
| Masa Min Antara Kegagalan (Galas) ~36,000 hours ~50,000 hours ~39% increase |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 1,500 ke atas 12,000 Ton metrik sejam (tph), bergantung kepada model dan bahan suapan.
Keperluan kuasa: Memandu motor dari 450 kW sehingga 1,200 kw. Electrical supply must be specified per regional standards (mis., 60Hz/4160V).
Spesifikasi Bahan: Kerangka utama keluli rekaan berkekuatan tinggi; aci utama keluli aloi palsu; manganese or chrome alloy concaves/mantles tailored to abrasion index.
Dimensi Fizikal (Model contoh): Jumlah ketinggian ~68m; berat dipasang antara 250 450 metric tons excluding feed hopper.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 40°C hingga +50°C. Dust suppression and heating systems available as options.

6. SENARIO APLIKASI

Projek Pembesaran Lombong Tembaga

Challenge A Tier1 copper miner needed to increase primary circuit throughput by 20% without expanding their footprint or overhauling existing feed conveyors.
Solution Installation of a new highcapacity gyratory crusher featuring an intelligent chamber profile designed specifically for their ore’s abrasiveness and work index.
Keputusan Mencapai peningkatan daya pengeluaran yang berterusan sebanyak 22%. The optimized wear profile extended concave service life by 18%, contributing to a project payback period of under three years based on increased production alone.

Naik Taraf Loji Pemprosesan Bijih Besi

Challenge Chronic downtime due to dust ingress causing bearing failures every 2430 months in a harsh desert environment.
Solution Retrofitted an existing gyratory crusher with our proprietary hybrid lubrication and multistage dust seal system during a scheduled reline.
Results Bearing inspection after 36 months showed no measurable contamination. The plant forecasts extending major bearing service intervals beyond 60 bulan, eliminating one full rebuild cycle per decade.

7. PERTIMBANGAN KOMERSIL

Peringkat Harga: Capital pricing is projectspecific based on size (4265”, dll.), spesifikasi bahan, dan kerumitan sistem kawalan. Budgetary quotes are provided following a review of feed material characteristics and capacity requirements.
Ciri Pilihan: Key options include automated lubrication systems specific grades alloy liners advanced condition monitoring sensors (vibration temperature) custom discharge conveyor configurations spare parts kits
Pakej Perkhidmatan: Choose from Foundation Supervision & Installation Commissioning Support MultiYear Maintenance Agreements Remote Diagnostic Support OnSite Training Programs
Pilihan Pembiayaan: We partner with leading industrial finance providers to offer competitive leasing structures milestonebased project financing solutions that align payments with your project’s cash flow timeline

8. Soalan Lazim

Q1 Are your gyratory crushers compatible with existing foundations from other OEMs?
A While dimensional standardization is limited we conduct full foundation analysis for retrofit projects Custom adapter rings or foundation modifications are engineered as part of the scope to ensure structural integrity

Q2 What is the typical lead time from order placement to commissioning?
A Lead times vary by size complexity For standard models in our portfolio expect manufacturing delivery within months Larger fully custom units may require months Detailed schedules are provided with formal proposals

Q3 How does implementing this equipment impact my ongoing operational staffing?
A Our designs prioritize serviceability reducing specialized labor requirements Field data indicates our liner systems can be handled by existing maintenance crews often without need for additional heavy lifting equipment onsite

S4 Apakah istilah komersial yang standard?
A Standard terms include progress payments tied to manufacturing milestones FOB our facility A performance bond can be provided Final retention payment is typically due upon successful completion of site acceptance tests

Q5 Can you provide wear parts after the initial sale?
A Yes We operate a dedicated parts division offering genuine wear parts concaves mantles etc Competitive lifecycle support packages are available to guarantee part availability optimize longterm operating costs