1. PEMBUKAAN PAINPOINT DRIVEN

Adakah anda menguruskan operasi penghancuran di mana kebolehpercayaan peralatan, penggredan produk yang konsisten, dan jumlah kos pemilikan secara langsung menentukan keuntungan? Untuk pengurus loji dan kontraktor kejuruteraan, cabaran dengan penghancuran primer boleh diukur. Masa henti yang tidak dirancang untuk penggantian mantel atau cekung boleh menghentikan keseluruhan baris pemprosesan, menelan belanja puluhan ribu sejam dalam pengeluaran yang hilang. Inconsistent feed size or moisture content can lead to choking, mengurangkan daya pengeluaran dan meningkatkan penggunaan kuasa setiap tan. Tambahan pula, the global push for responsible manufacturing means sourcing equipment that complies with environmental directives like RoHS is no longer optional but a prerequisite for many projects and tenders.

How do you achieve higher availability with lower maintenance labor? Can your primary crusher deliver a consistent product curve despite variable feed? Are your equipment partners providing verifiable compliance documentation for hazardous substance control? The solution lies in specifying a RoHS Compliant Gyratory Crusher from a manufacturer committed to both performance and material integrity.

2. GAMBARAN KESELURUHAN PRODUK

A RoHS Compliant Gyratory Crusher is a primary crushing machine designed for highcapacity, continuous operation in largescale mining and aggregate operations, built with strict adherence to the Restriction of Hazardous Substances (RoHS) arahan. This governs the use of specific hazardous materials in electrical components and certain mechanical alloys.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Large runofmine ore or quarry rock is directly dumped into the crusher’s receiving hopper above the spider assembly.
2. Tindakan Menghancurkan: The gyrating mantle eccentrically compresses material against the stationary concave liners, applying progressive compressive force to break particles.
3. Pelepasan: Bahan yang dihancurkan jatuh melalui graviti melalui jurang yang semakin berkurangan di bahagian bawah ruang dan keluar melalui bukaan pelepasan.

Skop Permohonan: Sesuai untuk hightonnage (1,500+ tph) primary crushing stations handling abrasive ores (besi, Tembaga, emas) dan batu keras. It is the preferred solution for slabby feed material due to its nonchoking design.

Batasan: Higher capital cost compared to jaw crushers; requires a substantial and stable foundation due to weight and dynamic forces; not suitable for portable plants or lowtonnage operations.

3. CIRI TERAS

Patented Liner Profiles | Asas Teknikal: Optimized crushing chamber geometry via DEM (Pemodelan Elemen Diskret) simulasi | Faedah Operasi: Achieves targeted product size distribution with up to 10% lower power draw per ton crushed | Kesan ROI: Reduced energy costs and extended liner life through even wear distribution.

Integrated Smart Chamber Relief System | Asas Teknikal: Hydraulicmechanical tramp release and clearing system with realtime pressure monitoring | Faedah Operasi: Automatically discharges uncrushable material and resets in under 60 saat, preventing damage to mainshaft and bearings | Kesan ROI: Eliminates hours of manual clearing downtime and avoids catastrophic failure repair costs.

RoHSVerified Component Sourcing | Asas Teknikal: Full material declarations from suppliers for electrical systems, anjing laut, pelincir, and specified alloys | Faedah Operasi: Ensures global market access, simplifies endoflife recycling, and mitigates supply chain risk related to noncompliant parts | Kesan ROI: Prevents project delays or rejections in regulated regions and futureproofs asset value.

Peripheral Spray System | Asas Teknikal: Programmable logiccontrolled dust suppression nozzles integrated into the base frame | Faedah Operasi: Effectively contains dust at discharge without oversaturating material | Kesan ROI: Mengekalkan pematuhan peraturan untuk pelepasan zarah, mengurangkan kos pembersihan, and improves site safety.

Falsafah Reka Bentuk Perkhidmatan Atas | Asas Teknikal: All routine maintenance tasks (Perubahan pelapik, pengubahsuaian lengan labah-labah) boleh diakses dari atas | Faedah Operasi: Reduces required service time by up to 30% compared to bottomservice designs; enhances safety by keeping personnel out from under suspended loads | Kesan ROI: Increases plant availability and lowers labor costs for planned maintenance events.

HighFidelity Condition Monitoring Ports | Asas Teknikal: Preinstalled sensor ports for vibration, suhu, and pressure on bearings and lubrication system | Faedah Operasi: Enables direct integration with plant PLC/SCADA for predictive maintenance scheduling | Kesan ROI: Mengubah penyelenggaraan daripada berasaskan kalendar kepada berasaskan keadaan, optimizing part inventory and preventing unplanned stops.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | RoHS Compliant Gyratory Crusher Solution | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Masa Pertukaran Pelapik| 2436 jam (manual jacking & pengendalian) | 1624 jam (integrated hydraulic assist & topservice)| Hingga 33% lebih pantas |
| Penggunaan Tenaga Khusus| Berbeza mengikut bijih; baseline established per project kWh/t| Ruang yang dioptimumkan & drive motor efficiency reduces draw| Didokumenkan 510% pengurangan |
| Masa Min Antara Kegagalan (Main Bearing)| ~60,000 operating hours with ideal conditions & pelinciran| >75,000 hours via advanced filtration & monitoring integration| >25% bertambah |
| Regulatory Documentation Depth| Certificate of Compliance only| Full material traceability dossier for major assemblies| 100% auditready compliance |
| Dust Emission at Discharge| Reliant on external spray systems often added postinstallation|< 10 mg/m³ with integrated, automated spray system factorytuned to crusher airflow| Meets stringent international standards at commissioning |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 1,500 ke atas 10,000 Ton metrik sejam (tph), bergantung pada saiz model, saiz suapan (F80), dan tetapan sisi tertutup (CSS).
Keperluan kuasa: Motor pemacu utama dari 300 kW sehingga 1 MW+. Supplied for voltages of 6.6kV or 11kV as standard; voltan lain yang tersedia.
Spesifikasi Bahan: Bingkai utama: Highstrength fabricated steel ASTM A36/A572. Concave/Mantle Liners: Manganese steel ASTM A128 Grade B2/B3+ or proprietary chromeenhanced alloys. Semua komponen elektrik (<1000V): Certified RoHS compliant.
Dimensi Fizikal: Berbeza dengan ketara mengikut model. Contoh (Medium Duty): Total height ~56m; installed weight (including base frame) ~250400 metric tons.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +50°C. Lubrication systems include heater/cooler packages as required. Dust sealing effective in environments with airborne particulate.

6. SENARIO APLIKASI

Copper Mine Expansion Project – Primary Crushing Circuit

Cabaran: An existing SAG mill feed circuit was bottlenecked by an aging primary crusher with frequent liner failures and excessive energy use (~0.85 kWj/t). The project had strict EUderived environmental procurement rules.
Penyelesaian: Installation of a new midsize RoHS Compliant Gyratory Crusher featuring smart chamber geometry and highefficiency drives.
Keputusan: Daya tampung meningkat sebanyak 18% while specific energy consumption dropped to 0.76 kWj/t. The provided full material compliance dossier satisfied the project’s green procurement requirements without delay.

Granite Aggregate Producer – HighAbrasion Quarry

Cabaran: Extremely abrasive granite was causing concave liner life of only 4 months in a standard gyratory crusher, leading to high consumable costs and unpredictable downtime.
Penyelesaian: Implementation of a heavyduty RoHS Compliant Gyratory Crusher configured with proprietary chromemoly liners and an optimized peripheral spray system to reduce dust without accelerating liner wear.
Keputusan: Hayat perkhidmatan pelapik dilanjutkan kepada lebih 6 months—a 50% improvement—reducing annual consumable spend by approximately onethird while maintaining consistent 8” product sizing.

Iron Ore Processing Plant – Capacity Upgrade

Cabaran: Need to increase plant capacity by >25%. Existing footprint was constrained; new equipment had to interface seamlessly with existing conveyors while offering higher reliability metrics.
Penyelesaian: A highcapacity RoHS Compliant Gyratory Crusher was selected based on its superior availability (>94%) metrics from field data in similar applications.
Keputusan: The crusher met all throughput targets within the existing footprint constraints. Plantwide availability improved due to reduced primary crushing section downtime, contributing directly to achieving annual production goals.

7 . PERTIMBANGAN KOMERSIL

Equipment pricing tiers are typically structured around throughput capacity , kuasa memandu ,and duty rating( mis., Kewajipan Standard , Tugas Berat , Tugas Berat Tambahan ) . Base capital investment reflects these core engineering parameters .

Optional features that provide operational value include:
Advanced predictive analytics software licenses .
Extended range lubrication conditioning units .
Specialized liner alloy packages( e.g.,for specific abrasion /impact conditions ) .
Spare part starter kits tailored to your planned maintenance schedule .

Service packages are available separately to support total cost management:
Preventive Maintenance Inspections : Scheduled audits performed by factorytrained technicians .
Onsite Repair & Overhaul Support : For major component replacement .
Remote Monitoring Support : Data analysis by application engineers .

Financing options for these capitalintensive solutions can include traditional equipment loans ,operating leases that may keep th e asset offbalancesheet ,or performancelinked agreements where repayments are partially tied to achieved throughput or availability metrics .

8 . Soalan Lazim

S1 : Apa yang boleh "RoHS Compliant" specifically mean for th e mechanical parts of a gyratory crusher ?
A1 : While th e RoHS directive primarily focuses on electrical/electronic components ,leading manufacturers extend this philosophy to th e entire supply chain . For mechanical assemblies ,this means verified documentation for restricted substances( like lead in certain bronzes or hexavalent chromium in coatings )i n any component where alternatives exist ,ensuring full traceability an d endoflife recyclability .

S2 : How does transitioning to a modern RoHS compliant model impact our existing ancillaries like feeders an d conveyors ?
A2 : These crushers are engineered for dimensional interoperability . Key interface points—feed opening dimensions ,discharge hopper connections ,an d foundation loading data—are designed to match or be easily adapted to industrystandard layouts . Our engineering review will confirm compatibility wit h your specific setup .

S3 : Can you quantify th e operational cost savings fro m features like th e smart chamber relief system ?
A3 : Field data shows that uncrushable material events( logam tramp ,bit gerudi )occur several times per year in typical operations . A traditional system may require a4 t o8 hour shutdown for manual clearing . Th e automated system addresses this i n under two minutes of stoppage . Preventing just one such event annually can save over $50k in lost production for a mediumsized operation .

S4 : Are spare parts an d wear liners for these crushers more expensive du e to compliance requirements ?
A4 : Not inherently . Th e compliance mandate drives supply chain optimization rather than cost inflation . Liners an d mechanical spares are competitively priced wit h noncompliant equivalents because they are sourced fro m certified foundries an d forgemasters using controlled materials . Th e value is i n risk mitigation—ensuring part availability without regulatory obstruction .

S5 : What is th e typical delivery lead time fro m order placement ?
A5 : Untuk model standard ,lead times range fro m9t o14 months ,depending on current foundry capacity an d component sourcing . This timeline accounts fo r engineering ,procurement of longlead items( like main shafts ),rekaan ,an d assembly . Expedited options may be available fo r critical path projects .

S6 : What training is provided fo r our maintenance crew ?
A6 Comprehensive training is included wit h purchase covering three areas :
1 )Operational overview fo r plant controllers .
2 )Routine inspection an d liner changeout procedures fo r millwrights .
3 )Diagnostics an d advanced troubleshooting fo r senior electricians/mechanics .
Training can be conducted at our facility during FAT( Ujian Penerimaan Kilang )o r onsite during commissioning