1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang semakin meningkat dan ketersediaan yang tidak dapat diramalkan menghakis keuntungan litar penghancur utama anda? Plant managers and engineering contractors consistently face critical challenges in gyratory crusher operations: excessive maintenance downtime for mantle and concave changes, penggunaan tenaga yang tinggi bagi setiap tan bahan yang diproses, and inconsistent feed opening performance leading to bottlenecks. Unplanned stoppages for repairs can cost tens of thousands per hour in lost production. Tambahan pula, premature wear on critical components directly increases your costperton metric.

How do you achieve higher throughput without a proportional increase in energy costs? Can you extend liner life to align maintenance with planned shutdowns? Is your primary crusher a reliable asset or a recurring source of operational risk? Addressing these questions is fundamental to securing a competitive edge in today’s market.

2. GAMBARAN KESELURUHAN PRODUK: PENGHANCUR GIRATOR UTAMA TUGAS BERAT

This heavyduty primary gyratory crusher is engineered for the first stage of crushing in hightonnage mining and aggregate operations. Ia direka untuk menerima bahan suapan runofmine terus daripada trak angkut, menyampaikan secara konsisten, coarse product for downstream processing.

Aliran Kerja Operasi:
1. Penerimaan Suapan: Large feed material is directed into the top of the crusher’s deep, kebuk penghancuran tidak tercekik.
2. Gyratory Crushing Action: The main shaft assembly, dengan mantel yang dipasang, gyrates within the stationary concave liners. This eccentric motion applies compressive force to the rock.
3. Pengurangan Progresif: Material is crushed continuously as it travels down through the chamber, reduced in size at each point until it meets the desired discharge setting.
4. Pelepasan: The crushed product exits through the bottom of the crusher, sedia untuk pengangkutan penghantar ke penghancuran sekunder atau penimbunan.

Skop Permohonan & Batasan:
Skop: Sesuai untuk kapasiti tinggi (1,500+ tph) primary crushing of hard rock (granit, basalt, bijih besi, bijih tembaga), overburden, and shot limestone. Sesuai untuk pemasangan loji tetap.
Batasan: Not designed for portable plants or recycling applications with significant tramp metal. Requires a stable concrete foundation and significant headroom for installation and maintenance.

3. CIRI TERAS

Reka Bentuk Cekung yang Dipatenkan | Asas Teknikal: bersegmen, pelapik boleh balik dengan profil yang dioptimumkan | Faedah Operasi: Enables faster liner changes by 40% and allows use of both sides for extended service life | Kesan ROI: Reduces labor costs per changeout and decreases liner inventory expenditure

Sistem Kawalan Pintar Bersepadu | Asas Teknikal: Pemantauan masa nyata cabutan kuasa, tekanan, and eccentric throw | Faedah Operasi: Automatically regulates feed rate to prevent overloads and optimizes cavity level for maximum throughput | Kesan ROI: Protects against costly mechanical damage events and improves energy efficiency by up to 8%

Reka Bentuk Cangkang Atas Tanpa Spider | Asas Teknikal: Eliminates traditional spider arms through a reinforced rimandhub structure | Faedah Operasi: Removes potential slurry pooling points and provides unobstructed feed opening | Kesan ROI: Reduces corrosionrelated maintenance and maximizes feed acceptance capacity

Pelepasan Tramp Hydroset™ & Menetapkan pelarasan | Asas Teknikal: Hydraulic cylinders support the main shaft for precise control | Faedah Operasi: Allows operators to adjust crusher gap settings under load and automatically release tramp iron | Kesan ROI: Minimizes downtime for product size changes and prevents catastrophic damage from uncrushables

HighTorque DirectDrive System | Asas Teknikal: Lowspeed synchronous motor coupled directly to the eccentric assembly | Faedah Operasi: Delivers constant crushing force across the entire stroke with higher mechanical efficiency than Vbelt drives | Kesan ROI: Mengurangkan penggunaan tenaga khusus (kWj/tan) and reduces drive system maintenance

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Penyelesaian Gyratory Crusher Kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Masa Pertukaran Pelapik (Major) | 48 72 jam | 24 36 jam | ~50% lebih pantas |
| Penggunaan Tenaga Khusus (kWj/tan) Garis dasar = X kWj/t| X kWj/tan| X 0.92 kWj/tan| Hingga 8% lebih rendah |
| Adanya (Dijadualkan & Tidak berjadual) | 92 94% annual average| >96% annual average| >2 mata peratusan lebih tinggi |
| Feed Opening Acceptable Fines Content (<100mm)| Limited to ~1015% before packing risk| Handles up to ~25% without choking| Significant flexibility in feed blend management |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 1,500 ke atas 12,000 Ton metrik sejam (tph), dependent on model selection and material characteristics.
Keperluan kuasa: Motor pemacu utama dari 450 kW sehingga 1 MW+. Complete system includes dedicated power for lubrication and hydraulic units.
Spesifikasi Bahan: Rangka utama dibina daripada keluli tuangan berintegriti tinggi; concaves and mantles available in premium manganese steel alloys; wear surfaces feature hardened steel bushings.
Dimensi Fizikal (Model Besar Biasa): Total height ~79 meters; installed weight ranges from ~250 to over 600 metric tons excluding feed hopper/discharge conveyors.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 40°C hingga +50°C. Dust sealing systems are rated for continuous operation in highdust environments.

6. SENARIO APLIKASI

Pengembangan Lombong Tembaga, Amerika Selatan

Cabaran: A major expansion required primary crushing capacity exceeding 8,000 tph of abrasive copper porphyry ore. The existing plant suffered from frequent concave cracking events causing unplanned downtime.
Penyelesaian: Installation of two largecapacity gyratory crushers featuring the patented spiderless top shell design and intelligent control system.
Keputusan: Mencapai daya pengeluaran yang berterusan sebanyak 8,400 tph. The robust top shell design eliminated stressrelated liner failures observed previously. Intelligent controls optimized load distribution across both units.

Granite Aggregate SuperQuarry, Amerika Utara

Cabaran: High operating costs driven by frequent manual crusher setting adjustments for different product grades and high energy consumption per ton.
Penyelesaian: Retrofit of an existing primary gyratory crusher with a modern Hydroset™ system and directdrive motor upgrade.
Keputusan: Crusher gap adjustments reduced from hours to under ten minutes via remote console control. The directdrive system lowered specific energy consumption by approximately seven percent annually.

7. PERTIMBANGAN KOMERSIL

Our gyratory crushers are offered under a tiered pricing structure based on size/capacity requirements:
Siri Tugas Standard: Untuk kapasiti sehingga ~4,000 tph; includes core features like Hydroset™ control.
Siri Tugas Berat: For capacities from ~4,000 – ~8 ,000 tph; adds enhanced monitoring systems as standard.
Super Heavy Duty Series: Untuk aplikasi berkapasiti ultra tinggi melebihi ~8 ,000 tph; includes full intelligent automation package.

Optional features include advanced predictive analytics software integration , specialized alloy liners for specific abrasion/corrosion conditions ,and automated lubrication systems .

Kami menawarkan pakej perkhidmatan yang komprehensif:
1 . Perjanjian Penyelenggaraan Terancang: Pemeriksaan berjadual , diskaun bahagian .
2 . Pakej Jaminan Prestasi: Includes guaranteed availability , throughput ,and liner life metrics .
3 . FullScope Lifecycle Contract: Meliputi semua bahagian , buruh ,and field service support .

Pilihan pembiayaan termasuk pembelian modal ,operating lease structures ,dan penyelesaian pembiayaan khusus projek yang disesuaikan untuk perbelanjaan modal yang besar .

8 . Soalan Lazim

S1 : Is this gyratory crusher compatible with my existing secondary crushing circuit or SAG mill feed preparation ?
A1 : ya . Our engineering team will review your target product size distribution ( JPA )to ensure optimal compatibility with your downstream processes .

S2 : What is the expected impact on my plant ’s overall electrical load ?
A2 : While individual motor sizes are significant ,the improved specific energy consumption often leads to lower overall kWh /ton processed compared to older technology .A detailed load analysis is part of our pre sales proposal .

S3 : How does your commercial offering handle long lead time components ?
A3 : Critical spare parts like main shaft assemblies are included in strategic stocking programs at our global service centers .Service agreements can guarantee parts availability within specified timeframes .

S4 : Apakah latihan yang disediakan untuk pasukan operasi kami ?
A4 : Kami menyediakan latihan di tapak yang komprehensif meliputi operasi biasa ,prosedur penyelenggaraan rutin ,and basic troubleshooting using our control system interfaces .

S5 : Can we retrofit some of these features onto our existing older model gyratory crushers ?
A5 : Select upgrades such as modern control systems or new concave designs may be available as retrofit kits .Feasibility depends on your machine ’s model age condition ;an audit can determine scope .

S6 : What are typical payment terms ?
A6 : Standard terms involve progress payments tied major manufacturing milestones shipment commissioning Custom terms may be structured based on project financing requirements .

Q7 How do you validate performance claims before purchase ?
A7 We provide extensive reference site contacts arrange site visits share anonymized operational data reports from similar installations Third party test reports on component durability are also available