1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable availability eroding your primary crushing circuit's profitability? For plant managers and engineering contractors, the primary crushing stage is a critical bottleneck where inefficiencies cascade through the entire processing line. Common challenges include:
Unscheduled Downtime: Premature wear of critical components like mantles and concaves leads to frequent, disruptive stoppages for maintenance, costing hundreds of thousands in lost throughput.
Inconsistent Feed Handling: Fluctuating feed sizes and material hardness cause chokefeeding issues or poor cavity utilization, reducing effective capacity and increasing power spikes.
High Operational Expenditure: The combined cost of energy consumption, liner replacements, and manual adjustment labor creates a significant ongoing financial burden.
Foundation & Installation Complexity: Traditional designs require massive, costly civil works and extended installation timelines, delaying project ROI.

What if your primary crusher could deliver higher availability, predictable maintenance cycles, and lower costperton metrics? The solution requires a design focused on durability, intelligent automation, and engineered efficiency.

2. PRODUCT OVERVIEW

The ODM Gyratory Crusher is a heavyduty, primary compression crusher engineered for the first stage of reducing runofmine ore or quarry rock. It is designed for hightonnage, continuous operation in fixedplant mining and aggregate production.

Operational Workflow:
1. Feed Intake: Large dump trucks or loaders deposit runofmine material into the topmounted feed hopper.
2. Compressive Crushing: The central gyrating mantle eccentrically rotates within the stationary concave, progressively crushing rock as it moves downward through the chamber.
3. Discharge: Crushed product exits through the bottom discharge opening (set by the mainshaft position) onto the primary conveyor for transport to downstream processes.

Application Scope: Ideal for highcapacity (1,500 12,000+ tph) primary crushing of abrasive hard rock (iron ore, copper ore, granite) and blastfragmented limestone. It is the preferred solution for largescale mining operations and major aggregate quarries.

Limitations: Not suitable for recycled concrete/asphalt or highly plastic/claybound materials. Requires a stable electrical power supply and significant capital investment best justified by longterm, highvolume production plans.

3. CORE FEATURES

Patented Concave Design | Technical Basis: Segmented, alloyoptimized liner system with interlocking geometry | Operational Benefit: Enables staged replacement of worn sections during planned maintenance windows; reduces changeout time by up to 30% compared to full concave replacement | ROI Impact: Lowers liner inventory costs and increases crusher availability by an average of 5% annually

Integrated Automatic Setting Regulation (IASR) | Technical Basis: Hydraulic control system linked to realtime motor power draw sensors | Operational Benefit: Automatically maintains closedside setting (CSS) to compensate for liner wear; prevents power overloads | ROI Impact: Maintains consistent product gradation and throughput; reduces energy waste; estimated 24% improvement in overall circuit efficiency

Spiderless Top Shell Design | Technical Basis: Eliminates traditional spider bridge; utilizes a singlepiece top shell with feed distribution lips | Operational Benefit: Removes a major maintenance component; allows safer, faster mantle installation/removal; prevents material bridging at feed entry | ROI Impact: Reduces major service downtime by up to two days per event; lowers labor costs and safety risks

Hydroset™ Tramp Release & Clearing System | Technical Basis: Dualacting hydraulic cylinders supporting the mainshaft | Operational Benefit: Provides instantaneous release from tramp iron events without stopping the crusher; allows cavity clearing in minutes versus hours | ROI Impact: Prevents catastrophic damage; field data shows a reduction in tramprelated downtime by over 90%

Direct Drive & Torque Limiting Coupling | Technical Basis: Lowspeed synchronous motor coupled directly to the eccentric via an air clutch with torque limiter | Operational Benefit: Eliminates Vbelt maintenance; provides smooth startup under load; protects gear train from shock loads | ROI Impact: Reduces annual drive system maintenance costs; improves power transmission efficiency by approximately 3%

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Baseline | ODM Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life (Abrasive Ore)| ~6 Months (Baseline) | Upgraded Manganese Steel & Profile Optimization| +1525% Extended Life |
| Tramp Iron Recovery Time| 48 Hours (Manual Clearing)
Hydroset™ Automated Cycle| <1 Hour |
| Energy Efficiency (kWh/ton)| Baseline = 100%
Direct Drive & Optimal Kinematics| ~7% Reduction in Specific Energy Consumption |
| Mantle Changeout Time| 2436 Hours
Spiderless Design & Tooling System| ~30% Faster Changeout |
| Availability (Annual)| ~9294%
Enhanced Reliability Features|<96% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 1,500 to over 12,000 metric tons per hour (tph), dependent on model selection and feed material.
Motor Power: Standard range from 450 kW to 1,200 kW (600 HP 1600 HP), with options for higher horsepower.
Feed Opening: Gape sizes from 1,000 mm to 1,500 mm.
Main Frame & Shells: Fabricated from hightensile steel plate with stressrelieved welding; critical areas feature additional wear protection.
Eccentric Assembly: Forged alloy steel eccentric bushing running in a precisionmachined bronze sleeve.
Dimensions & Mass: Approximate installed height ranges from 7m to 10m; total operating weight between 250 550 metric tons depending on model.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust sealing systems are standard for harsh environments.

6. APPLICATION SCENARIOS

Copper Mine Expansion

Challenge: A major copper operation needed to increase plant throughput by 25%. Their existing primary crusher was at maximum capacity with frequent linerrelated stoppages causing bottlenecking.
Solution: Installation of an ODM Gyratory Crusher with IASR automation was integrated into their expansion circuit.
Results: Achieved sustained throughput at design capacity of 6,500 tph. Liner life increased by 18%, contributing to an overall plant availability increase of 3%. The project met its tonnage uplift target within six months of commissioning.

Granite Aggregate Quarry Upgrade

Challenge: A large quarry supplying rail ballast faced inconsistent product sizing due to manual CSS adjustments on an aging gyratory crusher. This led to recrushing cycles and wasted capacity.
Solution: Replacement with an ODM Gyratory Crusher featuring the Integrated Automatic Setting Regulation system.
Results: Product gradation consistency improved dramatically (+/5mm tolerance held consistently). Yield of inspec product increased by an estimated 8%, directly improving revenue per ton crushed while lowering energy costs associated with reprocessing.

7. COMMERCIAL CONSIDERATIONS

ODM Gyratory Crushers are offered across three capability tiers:
Standard Duty Series: For consistent feed materials like limestone. Focus on costeffective reliability for aggregate producers.
Heavy Duty Series: Engineered for hard rock mining (copper iron gold ores). Includes upgraded liners bearings and sealing as standard
Super Duty Series: For ultrahigh tonnage megamine applications featuring enhanced monitoring systems premium metallurgy

Optional features include advanced condition monitoring sensors dust suppression ring packages automated lubrication systems

Service packages range from basic commissioning support up to comprehensive multiyear performance contracts covering parts planned maintenance

Financing options including equipment leasing project financing are available through partners subject to credit approval

8. FAQ

Q What infrastructure modifications are required when replacing an older gyratory crusher?
A The ODM design emphasizes footprint compatibility Our engineering team provides detailed foundation analysis Most models can utilize existing footings with minor modifications significantly reducing retrofit time cost

Q How does your automation system interface with our existing plant DCS/SCADA?
A The crushers PLCbased control system offers standard communication protocols Modbus TCP/IP Profinet etc allowing seamless data exchange for remote monitoring setpoint adjustment within your central control room

Q What is your lead time from order placement to shipment?
A Lead times vary based on model specification Current standard lead times range between 9 months We offer expedited manufacturing slots subject feasibility assessment

Q Do you provide performance guarantees?
A Yes we offer guaranteed capacity throughput based on agreed feed material specifications as well as guaranteed maximum specific energy consumption kWh/ton under defined operating conditions These are formalized within our commercial proposal

Q What training do you provide for our operations maintenance teams?
A We include comprehensive onsite training during commissioning covering safe operation routine maintenance procedures troubleshooting Classroom training manuals digital resources are also provided