1. PAINPOINT DRIVEN OPENING

Managing a premium iron ore crushing plant demands consistent throughput and cost control. Common operational challenges include:
Unplanned Downtime: Frequent liner changes and mechanical failures in primary crushers halt your entire processing line, costing thousands per hour in lost production.
Inconsistent Product Size: Fluctuations in feed size and hardness lead to poor fragmentation, overloading downstream circuits like grinding mills, which dramatically increases energy costs.
High Maintenance Costs: Abrasive iron ore rapidly wears crusher components, resulting in excessive spending on replacement parts and significant labor hours for upkeep.
Energy Inefficiency: Older crushing stages often operate at nonoptimal settings, consuming more power per ton of material processed than necessary.

Are you evaluating how to increase plant availability, reduce cost per ton, and achieve a more consistent feed for your beneficiation circuit? The foundation of this efficiency starts with your primary crushing solution.

2. PRODUCT OVERVIEW

This product line comprises heavyduty, stationary primary gyratory crushers engineered specifically for hightonnage, abrasive iron ore applications. As a private label manufacturer, we provide equipment built to your precise operational specifications and branding requirements.

Operational Workflow:
1. Runofmine (ROM) iron ore is fed via haul trucks or apron feeder into the crusher’s deep chamber.
2. The eccentrically rotating mantle continuously compresses ore against the concave liners, achieving size reduction through progressive rockonrock crushing.
3. Crushed material discharges via gravity through the bottom setting, ready for secondary crushing or direct conveyor transport.

Application Scope: Ideal for largescale mining operations with annual capacities exceeding 10 million tonnes of magnetite or hematite ores. Suitable for both greenfield installations and retrofit upgrades.

Limitations: Not designed for lowtonnage operations (< 2 million tonnes annually) or for processing highly plastic or sticky materials without specific feed system modifications.

3. CORE FEATURES

Patented Chamber Geometry | Technical Basis: Optimized nip angle and crushing stroke profile | Operational Benefit: Achieves targeted product size in a single pass more consistently, reducing recirculation load | ROI Impact: Up to 15% higher throughput compared to conventional chambers of similar intake size

Liner Life Enhancement System | Technical Basis: Automated liner condition monitoring and wear compensation technology | Operational Benefit: Maintains crusher setting automatically for stable output; provides predictive maintenance alerts | ROI Impact: Extends liner intervals by 2030%, reducing downtime and part costs

Hybrid Lubrication System | Technical Basis: Dedicated circuits for bearing lubrication and piston pressure with independent cooling | Operational Benefit: Ensures reliable operation under high dust load and variable ambient temperatures common in iron ore plants | ROI Impact: Reduces risk of bearingrelated catastrophic failure; field data shows a 40% improvement in mean time between failures (MTBF) for lubrication systems

Intelligent Drive & Control Integration | Technical Basis: Hightorque synchronous motor paired with variable frequency drive (VFD) control | Operational Benefit: Allows soft starts, power draw optimization, and adjustment of crushing speed to match ore characteristics | ROI Impact: Reduces peak electrical demand by up to 35% during startup; optimizes kWh per ton consumed

Modular Concave & Mantle Assembly | Technical Basis: Segmented liner design with mechanical locking | Operational Benefit: Enables faster liner changes using standard plant maintenance tools; reduces changeout time by up to 50% | ROI Impact: Lowers labor costs per maintenance event and increases plant availability

Integrated Dust Sealing & Containment | Technical Basis: Multistage labyrinth seals combined with positivepressure air barriers | Operational Benefit: Effectively contains dust particles at the feed and discharge points, critical for meeting site environmental standards | ROI Impact: Minimizes material loss and reduces cleanup costs, protecting downstream equipment from abrasive dust

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | This Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Scheduled Operating Time) | 92 94%| 96%+| ~34% increase |
| Tonnage Throughput (tph comparable size) Baseline = 100%| 100%| 108 115%| Up to 15% higher |
| Liner Wear Life (Million Tonnes Processed)| Varies by ore abrasiveness| +2030%| 2030% longer life |
| Specific Energy Consumption(kWh/t)| Baseline = 100%| 92 95%|58% reduction |
| Mean Time To Repair(Major Liner Change hours)| ~48 hours| <36 hours|25+% faster |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 5,000 to over 12,000 tonnes per hour (tph), depending on model selection and feed conditions.
Power Requirements: Drive motors from 600 kW up to 1.5 MW. Compatible with mediumvoltage supply (3.3 kV 6.6 kV). Full electrical package including VFDs and control panel is supplied.
Material Specifications: Main frame constructed from highintegrity cast steel. Concave liners available in premium manganese steel alloys or optional composite metal matrix materials for extreme abrasion resistance.
Physical Dimensions: Feed opening sizes from 1,200 mm to 1,500 mm. Overall installation footprint is customized per plant layout but is designed to minimize civil works requirements.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust sealing effective in conditions with airborne particulate levels exceeding 50 mg/m³.

6. APPLICATION SCENARIOS

LargeScale Hematite Operation – Throughput Expansion

Challenge: A major Australian mine needed to increase plant throughput by over 20% without expanding their primary crusher footprint or overloading existing conveyors.
Solution: Replacement of an older primary crusher with a highcapacity gyratory crusher featuring the Patented Chamber Geometry and Intelligent Drive system.
Results: Achieved a sustained 22% increase in average hourly tonnage through the primary circuit while reducing specific energy consumption by 7%. The consistent product size reduced bottlenecks at the secondary screening stage.

Magnetite Concentrator – Reducing Downtime

Challenge: A Canadian concentrator faced excessive unplanned downtime due to unpredictable liner wear in their primary crusher, causing scheduling conflicts with downstream grinding mills.
Solution: Installation of a gyratory crusher equipped with the Liner Life Enhancement System and Modular Concave Assembly.
Results: Liner change intervals became predictable within a ±5% window, allowing maintenance to be scheduled during planned mill stops. Total annual downtime attributed to primary crushing was reduced by approximately 180 hours.

7. COMMERCIAL CONSIDERATIONS

Our private label manufacturing model provides flexibility across commercial terms:

Equipment Pricing Tiers: Based on capacity rating and material specification choices (e.g., standard vs. premium liners). Options range from core crusher supply only to full packaged stations including feeders, walkways, and chute work.
Optional Features: Advanced condition monitoring sensors (vibration, temperature), automated setting adjustment systems (ASRi), specialized wear protection packages for specific ore geochemistry.
Service Packages: Tiered offerings include onsite supervision during commissioning; multiyear liner supply contracts with guaranteed wear rates; remote diagnostic support; and scheduled inspection services.
Financing Options: We work with international export credit agencies and equipment financing partners to offer leasetoown structures or term loans tailored to project finance requirements.

8. FAQ

1. How does this equipment integrate with our existing secondary crushing circuit?
The discharge setting is fully adjustable within its designed range to ensure optimal feed size distribution for your cone crushers or HPGRs.

2 What is the expected impact on our overall plant operating costs?
Industry data from comparable upgrades indicates a reduction in total cost per ton of crushed material between $0.15$0 .35 USD , primarily from lower energy use , extended wear part life ,and increased availability .

3 Are performance guarantees offered?
Yes . We provide contractual guarantees for rated capacity under defined conditions , specific energy consumption ,and major component wear life based on your provided ore characterization data .

4 What are the lead times for delivery ?
Lead times vary based on model complexity but typically range from9to14months exworksforafullycustomizedprimarycrusher . Expedited options may be available .

5 Do you provide supportfor foundation designand installation ?
We supply comprehensive foundation loading diagramsand interface drawings . Onsite technical supervision during installationand commissioningis available as partof our service packages .

6 Canyou accommodateour company’s brandingand documentation standards ?
Asa private label manufacturer ,thisisacore service . Equipment can bebadgedwithyourbrand,and all manuals ,drawings,and control system interfacescanbe formattedto your specifications .

7 Howdoesthe intelligent drive systemhandlepowerfluctuations commonatremote mine sites ?
The integrated VFDsystem includes line reactorsand harmonic filteringto protectthe motorfromgrid disturbances .Itcanalsobe configuredfor controlled shutdownsin caseofundervoltage events topreventmechanical damage