1. PAINPOINT DRIVEN OPENING

Managing a limestone quarry or processing plant presents distinct, costly challenges. Are you experiencing persistent bottlenecks that limit your operation’s true capacity? Common pain points include:
Excessive Primary Crusher Downtime: Bridging and clogging at the primary crushing stage due to oversized, slabby feed material halts entire production lines, costing thousands per hour in lost throughput.
Unpredictable Feed Size to Downstream Processes: Inconsistent fragmentation from the muck pile leads to poor crusher performance, increased wear on conveyor systems, and inefficient sizing for kiln feed or aggregate products.
High Operational Costs from Secondary Breakage: Reliance on hydraulic hammers for secondary breaking is laborintensive, slow, and incurs substantial costs in tool wear, fuel, and equipment maintenance.
Safety and Vibration Concerns: Secondary breaking and inefficient primary blasting can generate excessive ground vibration, posing regulatory compliance risks and community relation issues near sensitive boundaries.

The central question is: how can you achieve a consistently fragmented, optimally sized feed from the face to your primary crusher to maximize plant uptime and reduce downstream processing costs?

2. PRODUCT OVERVIEW

The solution is a highcapacity Primary Gyratory Crusher engineered specifically for hightonnage limestone mining operations. This equipment serves as the cornerstone of your raw material handling system, designed to accept runofquarry limestone directly from the haul trucks.

Operational Workflow:
1. Direct dump of shot limestone from haul trucks (up to 2meter top size) into the crusher’s large feed hopper.
2. The gyrating mantle within the fixed concave crushes material via compressive force, reducing it by a factor of 6:1 to 8:1.
3. Crushed product discharges onto the main plant conveyor at a consistent size (typically <250mm), ready for secondary crushing or screening.

Application Scope: Ideal for largescale quarry operations with annual production exceeding 1 million tons. It is designed for continuous, 24/7 operation under heavy load.

Limitations: Not suitable for smallscale quarries or portable crushing setups due to significant foundation requirements and capital investment. Requires consistent, planned maintenance shutdowns.

3. CORE FEATURES

Patented NonChoking Concave Profile | Technical Basis: Steepsided feed opening with optimized curvature | Operational Benefit: Eliminates bridging of slabby limestone; ensures continuous material flow even with high clay content | ROI Impact: Reduces crusher stall events by up to 90%, directly increasing available crushing hours

Integrated Automatic Setting Regulation (ASR) System | Technical Basis: Hydropneumatic adjustment with realtime position sensors | Operational Benefit: Maintains target discharge setting without manual intervention; compensates for mantle wear automatically | ROI Impact: Delivers consistent product sizing (+/ 5% tolerance), improving downstream efficiency and reducing product waste

HeavyDuty Main Shaft & Spider Assembly | Technical Basis: Forged alloy steel shaft with premium bronze bushing design | Operational Benefit: Withstands extreme shock loads from uncrushable material; provides reliable service life exceeding 10 years in abrasive limestone | ROI Impact: Lowers lifetime cost of ownership via extended major component life and reduced risk of catastrophic failure

Lube System with Dual Coolers & Filtration | Technical Basis: Redundant cooling circuits and offline filtration unit | Operational Benefit: Maintains optimal bearing temperature in highambient conditions; continuously purges contaminants from oil | ROI Impact: Extends bearing service intervals by up to 50%, decreasing lubrication costs and unplanned downtime

Smart Chamber Design & Wear Monitoring | Technical Basis: Modular concave segments with embedded wear sensors | Operational Benefit: Allows for strategic rotation/replacement of wear parts; provides predictive maintenance data on remaining liner life | ROI Impact: Optimizes liner changeout schedules during planned stops, maximizing utilization and parts investment

Centralized Greasing & PLC Control Hub | Technical Basis: Automated singlepoint greasing for all bearings integrated into plant control system | Operational Benefit: Simplifies routine maintenance; provides operators with realtime performance dashboards and fault diagnostics | ROI Impact: Reduces daily lubrication labor by 75% and shortens troubleshooting time significantly

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Cone/Jaw Crusher Plants) | Primary Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime)| 8590% due to bridging & more frequent liner changes| 9496% through nonchoking design & longer wear life| +7% operational availability |
| Tonnage per Installed HP| Lower ratio due to intermittent feeding & chamber design| Higher ratio via continuous crushing action & optimal kinematics| +1520% energy efficiency |
| Feed Top Size Capability| Limited by gape dimension; often requires prescreening| Accepts larger direct dump feed (up to 2m), simplifying loadout| Eliminates prescreening stage |
| Cost per Ton (Wear Parts)| Higher cost due to faster wear rates in abrasive limestone| Lower cost via massive liner design & strategic wear monitoring| 25% cost per ton crushed |
| Manpower for Operation| Often requires dedicated crusher operator/feeder watcher| Fully automated operation integrated with PLC/SCADA system| 1 FTE requirement |

5. TECHNICAL SPECIFICATIONS

Model Designation: GY5460 HD Limestone
Capacity Range: 2,500 – 4,500 tonnes per hour (dependent on CSS and material work index)
Feed Opening: 1,370 mm
Maximum Feed Size: 2,000 mm (slabby limestone)
Nominal Discharge Setting Range: 150 – 250 mm
Installed Power: 450 kW (600 HP) electric drive
Total Weight (Crusher Only): ~275 tonnes
Key Material Specifications: Mantle & Concaves – Manganese steel alloy with patented workhardening matrix; Main Shaft – Forged 34CrNiMo6; Base Frame – Fabricated heavyduty steel.
Physical Dimensions (LxWxH): ~6.5m x ~5m x ~4.5m (above foundation).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust sealing rated for IP66.

6. APPLICATION SCENARIOS

Large Cement Plant Quarry Integration

Challenge: A major cement producer faced inconsistent kiln feed quality due to fluctuating limestone size from their old jaw crusher circuit, causing inefficiencies in raw mill operation and higher specific energy consumption.
Solution: Installation of a GY5460 HD Primary Gyratory Crusher as the new first reduction stage.
Results: Achieved a consistent 200mm crusher product. This stabilized raw mill feed, resulting in a documented 8% reduction in specific energy consumption at the mill and a 12% increase in overall plant throughput due to eliminated upstream bottlenecks.

HighVolume Aggregate Quarry Expansion

Challenge: An aggregate producer needed to expand annual output but was constrained by primary crushing capacity. Their existing system required frequent secondary breaking and suffered from daily bridging incidents.
Solution: Commissioning of two parallel GY5460 HD crushers fed directly by 90ton haul trucks.
Results：Bridging incidents were eliminated. The quarry increased average hourly throughput by over 40%, meeting expansion targets without adding a third shift. Secondary hammer operating costs were reduced by over 60%.

7. COMMERCIAL CONSIDERATIONS

Equipment pricing is structured around configuration tiers:
Base Configuration Tier: Includes crusher, drive motor, lubrication system, and basic PLC controls.
Advanced Optimization Tier: Adds ASR System, integrated wear monitoring sensors, advanced predictive maintenance software suite.
Turnkey Installation Tier: Full engineering package including foundation design drawings, installation supervision,and commissioning services.

Optional features include dust suppression ring kits,tramp metal detection systems,and custom discharge conveyor flanges.

Service packages are offered as annual Performance Care Agreements covering planned inspections,predictive analytics review,and priority parts supply.Financing options include capital purchase,direct leasetoown models,and throughputbased agreements tailoredfor largescale projects.

8. FAQ

Q1：Is this primary gyratory crusher compatible with our existing downstream secondary cone crushersand screening plant?
A1：Yes.Field data shows its abilityto producea consistent,fineslimited product optimizes loadingand performanceof downstream stages.Engineering supportis providedto ensure interface compatibilitywith your existing conveyorsand chutework.

Q2：What isthe typical implementation timelinefrom orderto commissioning?
A2：Fora standard model,the lead timeis approximately89 months.Foundation constructioncan proceedin parallel upon receiptof detailed drawings.Onsite erectionand mechanical commissioningtypically require810 weekswith our supervision.

Q3：How doesthe automated setting regulationimpact final product specificationfor our aggregate products?
A3：The ASR systemmaintainsa tighter discharge setting tolerance.This directly translatesintoa more consistentfeedfor your secondary/tertiary stages,yielding superior controlover final aggregate gradationand increased yieldof inspecproduct.

Q4：What arethe critical spare partswe should planto stock?
A4：We recommendan initial spare parts kitincluding concave segments,mantle,bushing kits,and hydraulic cartridge filters.Ourbasedon your specific production forecastand local logisticsupport times.

Q5：Can this equipment handlethe occasional siliceous bandor chert nodulefoundin our limestone deposit?
A5：Yes.The heavyduty designincorporatesa hydroset systemthat allows the c rus herto pass uncrushablematerialby temporarily openingthe discharge setting,thereby providingprotection against tramp materialdamage.The robust main shaftassemblyis engineeredfor such shock loads.

Q6：What trainingis providedfor our maintenance crew?
A6：Comprehensive trainingis includedcovering operational procedures,scheduled maintenance tasks,troubleshooting usingthe PLC interface,and safety lockout protocols.This consistsof both classroominstructionand handson sessionsduring commissioning.

Q7：Are there financing options that align paymentwith achievingprojected production volumes?
A7：Yes.We offer structured financing solutionswhere repayment schedulescan be linkedto operational milestonesor throughput volumes.This helps manageinitial capital outlayand aligns ourobjectiveswith your production success