1. PEMBUKAAN PAINPOINT DRIVEN

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit’s profitability? Untuk pengurus loji dan kontraktor kejuruteraan, the primary crushing stage is a critical bottleneck where inefficiencies cascade downstream, directly impacting tonnage and bottom line. Common challenges with outdated or undersized gyratory crushers include:
Masa Henti Berlebihan untuk Penyelenggaraan: Traditional spider bushing or mantle changes can require 2448 hours of lost production, costing thousands per hour in idle processing capacity.
Unplanned Stoppages from Tramp Iron: Inadequate protection mechanisms lead to costly damage to head nuts, mainshafts, and bushings, resulting in sixfigure repair bills and extended outages.
Inconsistent Throughput & Saiz produk: Worn or poorly designed crushing chambers fail to maintain target discharge settings, causing fluctuations in feed to downstream SAG mills or secondary crushers, reducing overall plant efficiency by 515%.
Penggunaan Tenaga Tinggi setiap Tan: Inefficient crushing action and high friction points force drives to work harder, increasing power costs—often the single largest operating expense.

Is your operation equipped to handle harder ores and higher tonnage demands while controlling maintenance costs and maximizing uptime?

2. GAMBARAN KESELURUHAN PRODUK: GIRATORY CRUSHER

A gyratory crusher is a cornerstone of highcapacity primary crushing stations in mining and largescale aggregate operations. It utilizes a fixed conical shell (cekung) and a gyrating mantle mounted on an eccentric shaft to compress and fragment large feed material (up to 1.5m in size) against itself.

Aliran Kerja Operasi:
1. Suapan: Runofmine (ROM) ore or large quarry rock is directed into the top of the crusher via dump trucks, pemuat, atau corong suapan.
2. Tindakan Menghancurkan: The central shaft gyrates within the concave, creating a progressive crushing cavity that reduces material size with each cycle.
3. Pelepasan: Crushed material exits through the bottom of the crusher (tetapan sisi terbuka) onto a conveyor belt for transport to the next stage of processing.

Skop Permohonan: Ideal for very high throughput applications (2,000 10,000+ tph), processing hard abrasive ores (besi, Tembaga, emas) and massive aggregate rock. It is the preferred solution for stationary inpit or underground primary crushing installations.

Batasan: Requires a substantial capital investment and reinforced concrete foundation. Tidak sesuai untuk operasi lowtonnage (<1000 tph), highly plastic or clayrich materials, or portable plant applications where mobility is required.

3. CIRI TERAS

Reka Bentuk Labah-labah Dipatenkan | Asas Teknikal: TopServiceable architecture with rim liners | Faedah Operasi: Enables all maintenance—including spider arm liners, anjing laut, and bushings—to be performed from above without dismantling the hydraulic cylinder or bottom shell. | Kesan ROI: Reduces scheduled maintenance downtime by up to 40%, meningkatkan waktu pengeluaran tahunan yang tersedia.

Integrated Tramp Iron Relief System | Asas Teknikal: Hydraulic support cylinder with automated pressure sensing & release | Faedah Operasi: Automatically discharges uncrushable material by lowering the mainshaft assembly, preventing damage to critical internal components. | Kesan ROI: Eliminates catastrophic failures from tramp metal; field data shows a reduction in related unplanned downtime by over 90%.

Constant Liner Performance (CLP) Reka Bentuk Dewan | Asas Teknikal: Computeroptimized concave and mantle profiles | Faedah Operasi: Maintains a consistent feed opening and product gradation throughout the liner’s life cycle without manual adjustment. | Kesan ROI: Delivers more stable throughput to downstream circuits; industry testing demonstrates a 7% increase in average tons processed between liner changes.

HighPressure Lubrication System | Asas Teknikal: Dualcircuit filtration with temperature monitoring | Faedah Operasi: Ensures positive oil flow to all critical bearings and gears under peak load conditions, minimizing frictioninduced wear. | Kesan ROI: Extends bearing service life; documented cases show intervals exceeding 50,000 jam, reducing spare parts inventory costs.

Direct Drive Configuration | Asas Teknikal: Lowspeed synchronous motor coupled directly to the eccentric via a fluid coupling or clutch | Faedah Operasi: Eliminates Vbelt drives and associated alignment issues; provides full torque at startup under load with higher transmission efficiency. | Kesan ROI: Improves energy efficiency by approximately 35% compared to traditional indirect drives.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Penyelesaian Gyratory Crusher Kami | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Adanya (Scheduled Maintenance) | ~92% 94% | >96% documented fleet average| +3% (+250+ operational hours/year) |
| Penggunaan tenaga (kWj/tan) | Berbeza mengikut bijih; garis dasar = 100%| Ruang yang dioptimumkan & direct drive reduce consumption| 4% typical reduction |
| Liner Changeout Time (Spider/Mantle) | 36 48 jam| Topservice design streamlines process| Downtime reduced by ~35% |
| Masa Min Antara Kegagalan (MTBF) Galas| ~30,000 40,000 jam| Advanced lubrication & sealing extends life| >25% bertambah |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 2,000 ke atas 12,000 Ton metrik sejam (tph), bergantung pada model dan bahan suapan.
Kuasa motor: Standard range from 450 kW sehingga 1,200 kw (600 1,600 Hp).
Pembukaan suapan: Gape sizes from 1,070 mm (42”) ke 1,520 mm (60”).
Bingkai utama & Cekung: Fabricated from highstrength steel; concaves available in alloy steel or composite metal matrix materials for specific abrasion/impact conditions.
Dimensi & Berat: Approximate installed height ranges from 6m to 9m; total operating weight between 250 550 tan metrik.
Julat Operasi Persekitaran: Designed for ambient temperatures from 40°C to +50°C with appropriate lubrication systems; dust seals rated for harsh particulate environments.

6. SENARIO APLIKASI

Pengembangan Lombong Tembaga Berskala Besar

Cabaran: A tier1 copper operation needed to increase primary crushed throughput by 25% without expanding their existing crusher footprint or foundation. Their legacy equipment could not achieve higher capacity without risking reliability.
Penyelesaian: Implementation of a new highcapacity gyratory crusher featuring an optimized CLP chamber design and direct drive system.
Keputusan: Achieved targeted throughput increase of 26% within the same footprint while reducing specific energy consumption by 3%. Plant availability improved due to reduced mechanical complexity.

Granite Aggregate Quarry Upgrade

Cabaran: Unplanned downtime from tramp steel (gigi baldi, bit gerudi) was causing frequent damage and over $200k annually in repair costs and lost production at a major quarry.
Penyelesaian: Retrofit of an existing primary gyratory station with an integrated hydraulic tramp iron relief system and updated control logic.
Keputusan: Virtually eliminated major damage events from tramp iron within one year. The system successfully discharged uncrushables on twelve occasions without incident, protecting core components.

7. PERTIMBANGAN KOMERSIL

Gyratory crushers represent a significant capital investment tailored precisely to project requirements.

Peringkat Harga: Capital cost is primarily determined by size/capacity (mis., 8ktph models), drive type choice standard vs hightorque),and material specifications standard vs heavyduty alloys).
Ciri Pilihan: Key upgrades include advanced condition monitoring sensors predictive maintenance), automated setting adjustment systems remote CSS control),and special wear packages for highly abrasive ores).
Pakej Perkhidmatan: Comprehensive plans are available covering scheduled inspections parts kits,and expert field service).These range from basic technical support up through fullperformance guaranteed contracts ensuring uptime targets are met).
Pilihan Pembiayaan: To support cash flow management flexible financing structures including leasing longterm rental,and projectbased financing can be arranged aligning payment schedules with operational revenue).

8.Soalan Lazim

Q What factors determine whether I need agyratorycrusher versus alarge jawcrusher?
A The decision typically hinges on required throughput total costofownership analysis,and feed material characteristics.Gyratories are generally favored for capacities above1200tph continuous operation on hard abrasive materials where their lower installed height relativetofeedsize provides an advantage.Jawcrushers may be preferredfor lowercapacity applications lessabrasive rockor where modularityis key).

Q How doesyourgyratorycrusherhandle wet sticky ore which can cause packing?
A Specific chamber designs combinedwith enhanced discharge arrangements help mitigate packing.The useof nonchoking concaves alongwith controlled feed distribution reduces this risk.For severe conditions we recommend sitespecific testingto determine optimal configuration).

Q Whatisthe typical lead timefor anewgyratorycrusher?
A For standard models lead timesrange from10to14monthsfrom orderto delivery factoring engineering procurement manufacturing assembly testing.This underscores importanceof early engagement during project feasibility studies).

Q Can yourmoderngyratorycrusherbe integratedintoour existingplant automation system Level2/3)?
A Yes ourcrush erscome standardwith modern PLCcontrol systems that provide open communication protocols OPC UA Modbus TCP/IP enabling seamless integration into widerplant SCADAand process control networksfor centralized monitoringand optimization).

Q Are there financing options availablethat includemaintenance services?
A Yes we offer bundled solutions that combine equipment financingwith comprehensive service agreements.This createsa predictable operational expenditure model covering both capital amortizationand routine maintenance parts protecting against budget overruns).