1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang semakin meningkat dan ketersediaan yang tidak dapat diramalkan menghakis keuntungan litar penghancur utama anda? Untuk pengurus loji dan kontraktor kejuruteraan, the primary crushing stage is a critical bottleneck where equipment failure translates directly into substantial financial loss. Cabaran biasa dengan penghancur gyratory yang lapuk atau kurang berprestasi termasuk:

Masa Hentian Tidak Dirancang yang Berlebihan: Kegagalan mekanikal yang kerap, Perubahan pelapik, and maintenance events halt entire processing lines. Industry data indicates that each hour of crusher downtime can cost operations over $10,000 in lost production.
Spiraling Maintenance & Kos Alat Ganti: Premature wear on mainshafts, cekung, and mantles leads to high consumable expenses and laborintensive replacement cycles.
Inconsistent Throughput & Saiz produk: Inability to maintain target capacity and product gradation under varying feed conditions, causing downstream inefficiencies in secondary crushing and milling.
Penggunaan Tenaga Tinggi: Older designs with inefficient crushing chambers and drive systems consume excessive power per ton of processed material.

Adakah operasi anda dilengkapi untuk mengendalikan peningkatan kekerasan bijih dan permintaan pemprosesan sambil mengawal kos? Penyelesaiannya terletak pada menentukan moden, highperformance gyratory crusher engineered for reliability and total cost of ownership.

2. GAMBARAN KESELURUHAN PRODUK: GIRATORY CRUSHER

Penghancur gyratory adalah skala besar, stationary primary crushing machine central to mineral processing and aggregate production plants. It operates via a gyrating mantle within a concave housing, menggunakan daya mampatan untuk mengurangkan bijih lombong besar atau batu kuari (biasanya sehingga 1500mm) to a conveyable size for downstream processing.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Large dump trucks or loaders deposit material into the crusher’s topmounted feed hopper.
2. Penghancuran Mampatan: The central mantle gyrates eccentrically within the stationary concave liners, continuously nipping and crushing material as it moves downward through the chamber.
3. Kawalan Tetapan Pelepasan: The crushed product exits at the bottom through the discharge opening (OSS). The crusher’s hydraulic setting adjustment system allows for precise control of product size without stopping operation.
4. Pengangkutan Bahan: Crushed output is conveyed to the next stage in the beneficiation or sizing circuit.

Skop Permohonan & Batasan:
Skop: Sesuai untuk hightonnage (1,500 – 12,000+ tph) aplikasi penghancuran utama dalam perlombongan batu keras (Tembaga, bijih besi, emas), kuari agregat berskala besar, dan operasi mineral perindustrian.
Batasan: Not suitable for smallscale operations or highly abrasive recycling materials where jaw crushers or impactors may be more appropriate. Memerlukan pelaburan modal yang besar dan asas konkrit bertetulang.

3. CIRI TERAS

Profil Cekung yang Dipatenkan | Asas Teknikal: Sudut nip yang dioptimumkan & geometri ruang menghancurkan | Faedah Operasi: Delivers consistent reduction ratio with lower risk of bridging/choking; menggalakkan penghancuran antara zarah untuk kecekapan | Kesan ROI: Data medan menunjukkan sehingga 8% higher throughput with more consistent product sizing, maximizing downstream circuit yield.

Aci Utama Bersepadu & Perhimpunan eksentrik | Asas Teknikal: Aci keluli aloi palsu dengan precisionmesin sipi | Faedah Operasi: Provides exceptional strength against shock loads from uncrushable material; ensures smooth gyration for reduced vibration | Kesan ROI: Extends major component life by years, deferring multimillion dollar replacement costs.

Automated Wear Monitoring System | Asas Teknikal: Realtime liner thickness tracking via sensors | Faedah Operasi: Your operators receive predictive alerts for liner wear, enabling planned maintenance during scheduled stops | Kesan ROI: Eliminates unplanned outages due to liner failure; optimizes liner utilization for up to 15% lower consumable cost per ton.

Pelarasan Tetapan Hidraulik & Perlindungan beban | Asas Teknikal: Dualfunction hydraulic piston beneath the main shaft | Faedah Operasi: Membenarkan pelarasan jauh tetapan nyahcas penghancur dalam beberapa minit berbanding jam; automatically releases tramp iron/uncrushables by lowering the main shaft | Kesan ROI: Minimizes noncrushing time for adjustments; prevents catastrophic damage from overloads, avoiding weeks of downtime.

StateofGear Drive System | Asas Teknikal: Hightorque synchronous motor coupled with helical gear drive | Faedah Operasi: Delivers more direct power transmission than traditional Vbelt drives with higher mechanical efficiency | Kesan ROI: Ujian industri menunjukkan 35% lower energy consumption per ton crushed compared to legacy drive systems.

Pelinciran Berpusat & Cooling System| Asas Teknikal: Dedicated closedloop oil circulation with temperature control| Faedah Operasi: Ensures critical bearings operate within optimal temperature range under maximum load| Kesan ROI: Directly extends bearing service life by preventing thermal degradation; reduces lubrication oil consumption by over 20%.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Penyelesaian Gyratory Crusher Kami | Kelebihan Berdokumen |
| : | : | : | : |
| Ketersediaan Mekanikal (tahunan) | 92 94% | 96 97%| +3% Penambahbaikan |
| Masa Pertukaran Pelapik (Major) | 48 72 jam| 24 36 jam| ~50% Pengurangan |
| Penggunaan Tenaga Khusus (kWj/t) Berbeza mengikut bahan.| Garis dasar = 100%| 93 95%| 57% Penambahbaikan |
| Masa Min Antara Kegagalan (MTBF) Komponen Kritikal| ~12 Bulan| 18+ berbulan-bulan| +50% Penambahbaikan |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 1,500 ke atas 12,000 Ton metrik sejam (tph), dependent on model selection and feed material characteristics.
Keperluan kuasa: Pandu rating motor dari 300 kW sehingga 1,200 kw (400 HP – 1,600 Hp), disesuaikan dengan keperluan tugas.
Spesifikasi Bahan: Highstrength fabricated steel base; Martensitic steel alloy main frame; Pelapik cekung dan mantel keluli mangan; Aci utama keluli aloi palsu.
Dimensi Fizikal (Model Besar Biasa): Jumlah ketinggian ~68m; Feed opening up to ~1.5m diameter; Gross weight between ~150 – 400 tan metrik.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 40°C hingga +50°C. Dustsealed construction meets IP65 standards where required.

6. SENARIO APLIKASI

Projek Pembesaran Lombong Tembaga

Cabaran: An existing copper mine’s expansion required a primary crusher capable of handling an additional 4,000 tph of harder sulfide ore without expanding the footprint of the coarse ore bin area.
Penyelesaian: Installation of a single highcapacity gyratory crusher with an optimized chamber profile designed for competent ore.
Keputusan: Mencapai daya pengeluaran yang berterusan sebanyak 4,200 tph at a finerthanplanned product size (P80), improving downstream SAG mill throughput by an estimated 6%. The singleunit solution saved an estimated 15% in associated civil works versus a twocrusher alternative.

Naik Taraf Kuari Agregat Granit

Challenge A major quarry operator faced rising maintenance costs and unpredictable breakdowns with an aging primary crusher, threatening key supply contracts that demanded consistent output.
Solution Replacement with a modern gyratory crusher featuring automated wear monitoring and hydraulic setting adjustment.
Results Mechanical availability increased from 89% ke 96%. Product consistency improved significantly reducing recirculation load The predictive maintenance system enabled liner changes during weekly conveyor belt maintenance eliminating unplanned stops

Loji Pemprosesan Bijih Besi

Challenge An iron ore plant experienced frequent chokeups in its primary circuit due to sticky feed material combined with high clay content leading to excessive cleanout downtime
Solution Implementation of a gyratory crusher with a nonchoking concave profile design specifically selected for stickyfeed applications
Results Crusher bridging incidents reduced by over 80%. Combined with the unit s robust overload protection system this change contributed directly to a 5 increase in overall plant monthly throughput

PERTIMBANGAN KOMERSIL

Gyratory Crushers represent a significant capital investment priced according to size capacity and configuration

Peringkat Harga Peralatan:
Base Model Range Designed for standard duty applications typically priced from approximately $750000 USD ke atas
Heavy Duty Configuration Includes upgraded components like forged shafts enhanced lubrication systems etc Premium reflects extended durability often starting around $12 juta USD
Fully Customized Solutions Engineered for specific site constraints or extreme duty Premium varies based on engineering scope

Ciri Pilihan:
Automated Wear Monitoring Package
Dust Suppression Sealing Kits
Advanced Vibration Analysis Sensors
Specialty Liner Alloys eg For ChromeMoly Steel

Pakej Perkhidmatan:
Standard Warranty Comprehensive parts coverage typically months on major components
Extended Service Plans Annual fixedcost plans covering parts labor inspections
OnSite Operator Training Programs

Pilihan Pembiayaan:
Capital Lease Structures preserving working capital
Operating Lease Agreements offering potential offbalancesheet treatment
ProjectBased Financing Available through partner institutions for qualifying developments

Soalan Lazim

What are the key factors determining whether my site needs a jaw or gyratory crusher?
Primary selection criteria are required capacity feed size top lump dimension abrasiveness index Gyratory crushers are typically specified for capacities exceeding tph where their continuous action offers efficiency advantages over cyclic jaw action

How does your design address longterm wear on critical components like the mainshaft?
Our design utilizes finite element analysis FEA during engineering ensuring optimal stress distribution We specify forged alloy steel shafts hardened at critical bearing surfaces This combined with our dedicated lubrication system results in demonstrably longer service intervals than cast component alternatives

Can this equipment integrate into our existing PLC/SCADA control system?
Yes Modern units come equipped with industrystandard communication protocols such as Profibus Modbus TCP/IP Integration documentation is provided allowing your engineering team or ours during commissioning establish full monitoring capability from your central control room

What is involved in installation what are typical lead times?
Installation requires prepared reinforced concrete foundations heavylift craneage mechanical assembly electrical connection Commissioning support is strongly recommended Lead times vary significantly based on model complexity but typically range from months exworks after final design approval A detailed project schedule is provided upon quotation

Adakah anda menawarkan jaminan prestasi?
Yes We provide contractual performance guarantees based on mutually agreed test protocols These typically cover rated throughput at specified discharge settings power consumption limits Availability guarantees can be included as part of comprehensive service agreements