1. PEMBUKAAN PAINPOINT DRIVEN

Adakah peningkatan kos operasi dan ketersediaan yang tidak dapat diramalkan menghakis keuntungan litar penghancur utama anda? Untuk pengurus loji dan kontraktor kejuruteraan, the primary crusher is a single point of failure with severe financial consequences. Cabaran biasa termasuk:

Masa Henti Tidak Berjadual: Premature wear of critical components like mantles and concaves leads to failure, menyebabkan terhenti pengeluaran yang menelan belanja puluhan ribu sejam dalam pengeluaran yang hilang.
Kos Penyelenggaraan Tinggi & Buruh: Kerap, manual adjustments for wear compensation are laborintensive and hazardous. The high cost and long lead times for massive replacement parts directly impact your maintenance budget.
Saiz Produk Tidak Konsisten: Worn or poorly configured crushers produce outofspec feed for downstream processes, reducing screening efficiency and overworking secondary crushers, which increases power consumption across the entire plant.
Penggunaan Tenaga Tinggi setiap Tan: An inefficiently operating gyratory crusher with poor kinematics or excessive friction can consume 1525% more power to achieve the same throughput, a direct hit to operational expenditure.

Is your operation managing these reactive costs, or is it time to invest in a primary crushing solution engineered for predictable performance and total cost of ownership?

2. GAMBARAN KESELURUHAN PRODUK

The Industrial Gyratory Crusher remains the cornerstone of hightonnage, hardrock mining and aggregate processing operations. Designed for firststage reduction of runofmine ore or quarried rock, it delivers consistent, highcapacity crushing where jaw crushers reach their volumetric limit.

Aliran Kerja Operasi:
1. Suapan: Large dump trucks or loaders deposit runofmine material into the rugged feed hopper.
2. Menghancurkan: The central vertical shaft with a mantle gyrates within a stationary concave, applying compressive force to reduce material size through progressive crushing stages.
3. Pelepasan: Produk yang dihancurkan keluar melalui bukaan pelepasan bahagian bawah (gape), with size controlled by the specific mantle position and stroke characteristics.

Skop Permohonan & Batasan:
Skop: Ideal for continuous, hightonnage (1,000+ Tph) primary crushing of abrasive ores (besi, Tembaga, emas) dan batu keras (granit, basalt). Essential for largescale mining and megaquarry operations.
Batasan: Not suitable for lowtonnage applications (<500 Tph) kerana kos modal yang tinggi. Requires significant foundational support and elevated headroom. Less effective for highly plastic or claybound materials without prescreening.

3. CIRI TERAS

Cekung yang dipatenkan & Profil Mantle | Asas Teknikal: Computeroptimized crushing chamber geometry | Faedah Operasi: Delivers a consistent product gradation curve throughout the liner's service life, reducing downstream process variability | Kesan ROI: Maintains optimal screening and secondary crushing efficiency, protecting overall plant yield.

Integrated Automatic Wear Compensation | Asas Teknikal: Hydraulic piston system with realtime position monitoring | Faedah Operasi: Maintains crusher setting automatically without manual intervention, eliminating downtime for adjustment | Kesan ROI: Increases mechanical availability by up to 3% annually and reduces labor exposure to confined spaces.

HighStrength Mainshaft Design | Asas Teknikal: Forged alloy steel shaft with fatigueresistant metallurgy | Faedah Operasi: Provides exceptional resilience against shock loads from uncrushable material (besi gelandangan) | Kesan ROI: Minimizes risk of catastrophic shaft failure, avoiding weeks of downtime and a sixfigure replacement part cost.

Sistem Pelincir dengan Pemantauan Keadaan | Asas Teknikal: Dualcircuit filtration with temperature and flow sensors feeding into plant DCS/SCADA | Faedah Operasi: Ensures positive pressure oil film protection for bearings; provides early warning of contamination or component distress | Kesan ROI: Memanjangkan hayat perkhidmatan galas sehingga 40%, preventing forced outages and enabling planned maintenance.

Pilihan Reka Bentuk Tanpa Spider | Asas Teknikal: Eliminates the traditional top spider assembly through a cantilevered shaft support system | Faedah Operasi: Allows for faster mantle changeout by removing a major structural obstacle; memudahkan akses penyelenggaraan | Kesan ROI: Mengurangkan masa henti pertukaran pelapik lebih kurang 30%, translating directly to additional production hours annually.

Sistem Pemacu Hibrid | Asas Teknikal: Combination of Vbelt transmission and direct lowspeed synchronous motor drive options tailored to site power infrastructure| Faedah Operasi: Offers flexibility in installation; Vbelt option provides inherent torque limitation protection; direct drive maximizes transmission efficiency| Kesan ROI: Enables optimal capital expenditure based on existing plant design while ensuring operational reliability.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Penyelesaian Gyratory Crusher Kami | Kelebihan Berdokumen |
| : | : | : | : |
| Ketersediaan Mekanikal (tahunan) | 92 94% | 96 97%| +3% Penambahbaikan |
| Kehidupan Pelapik Purata (Bijih Pelelas) | 6 8 berbulan-bulan| 9 11 berbulan-bulan| +35% Penambahbaikan |
| Penggunaan tenaga (kWj/tan) Baseline = X kW/t| X kW/t| X 0.85 kW/t| 15% Penambahbaikan |
| Tramp Steel Recovery Time (Full Chamber Clear)| ~8 Hours Manual Process|<4 Hours w/ Hydraulic Clearing Jacks |50% Downtime |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 1,500 ke atas 10,000 tan metrik sejam (MTPH), bergantung pada bahan suapan dan tetapan sisi tertutup (CSS).
Keperluan kuasa: Pandu rating motor dari 300 kW sehingga 1 MW+; voltage adaptable to site specifications (mis., 6.6 kV).
Spesifikasi Bahan: Mantel & cekung tersedia dalam aloi keluli mangan premium; optional chrome white iron inserts for extreme abrasion zones; aci utama ditempa daripada keluli NiCrMo berkekuatan tinggi.
Dimensi Fizikal / Jejak: Typical model footprint diameter ranges from ~5m to >8m; total installed height ranges from ~7m to >12m.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 40°C hingga +50°C; pengedap habuk dinilai untuk perlindungan IP66; sistem pelinciran termasuk pakej pemanas/penyejuk mengikut keperluan.

6. SENARIO APLIKASI

Pengembangan Lombong Tembaga Berskala Besar

Cabaran: A planned expansion required a ~40% increase in primary crushed throughput without enlarging the existing crusher station footprint or foundations. The existing equipment could not be modified to meet the new capacity target.
Penyelesaian: Implementation of our nextgeneration gyratory crusher featuring an optimized stroke profile and highercapacity drive system designed as a direct replacement within spatial constraints.
Keputusan: Mencapai peningkatan daya pengeluaran yang berterusan sebanyak 42%. Field data shows energy efficiency improved by 18% per ton crushed due to advanced chamber kinematics.

Granite Aggregate Quarry Seeking Consistency

Cabaran: Inconsistent product shape from an aging primary crusher caused excessive wear on downstream cone crushers and poor yield on premium chip sizes critical for asphalt mixes.
Penyelesaian: Installation of our gyratory crusher with computermodeled concave profiles specifically tuned for granite fragmentation characteristics.
Keputusan: Achieved a more cubical primary product shape factor improvement of over 22%. This reduced recirculating load in secondary circuits by an estimated 15%, lowering total plant power consumption while increasing saleable product yield.

7. PERTIMBANGAN KOMERSIL

Our industrial gyratory crushers are offered under three primary commercial frameworks:

1. Standard Capital Purchase Tier: Includes the core crusher assembly with standard drive motor options and basic instrumentation suitable for integration into existing control systems.
2. Peringkat Prestasi Dipertingkat (EPT): Bundles advanced features such as Integrated Automatic Wear Compensation as standard along with predictive health monitoring sensors preinstalled at key points on bearings,lube system,and mainshaft position.This tier includes extended warranty terms on major castings.
3. Ciri Pilihan & Naik taraf:
Spiderless design package
Automated tramp release & clearing system
Advanced liner bolt tensioning systems
Full OEMsupplied lubrication skid

Service packages range from basic technical documentation support through comprehensive multiyear Performance Assurance Agreements covering planned maintenance,pemeriksaan,and guaranteed parts availability.Financing options including leasetoown structures are available through our industrial finance partners,moving capital expenditure towards operational expenditure where beneficial

Soalan Lazim

Q1 How do I determine if my existing foundation can support your gyratory crusher?
A Our engineering team provides full foundation loading diagrams specific to each model.We conduct a comparative analysis against your existing drawings.Foundation modifications are often not required when replacing older units due our designs focus on optimizing mass distribution

Q2 What is the typical lead time between order placement commissioning?
A Lead times vary based on model complexity size.For standard configurations lead time typically ranges between months months including manufacturing testing delivery Critical path items like large castings are managed through strategic inventory programs

Q3 How does your automatic wear compensation system interface with my plant’s Distributed Control System DCS?
A The system provides standard Modbus TCP/IP Profinet outputs transmitting realtime data such as CSS position hydraulic pressure operator alerts This allows seamless integration into most modern control rooms condition monitoring platforms

Q4 Are there specific training requirements operators maintenance crews?
A Yes We provide structured training programs both at commissioning onsite covering safe operation routine inspections basic troubleshooting procedures Training focuses maximizing equipment life recognizing early signs component wear

Q5 What is your policy regarding nonOEM spare parts compatibility?
A While we engineer test guarantee performance using genuine OEM parts we provide clear technical specifications thirdparty manufacturers However use nonspecified parts particularly critical wear components may void warranty coverage related assemblies We document this transparently commercial agreements