1. ABERTURA ACIONADA POR PAINPOINT

Are you managing escalating maintenance costs and unpredictable downtime in your cement production line? The critical process of material size reduction directly impacts your plant's throughput, energy expenditure, and product quality consistency. Common challenges with outdated or underperforming crushing equipment include:

Consumo excessivo de energia: Inefficient crushers can account for over 30% of your milling circuit's power draw, corroendo diretamente as margens de lucro.
Tempo de inatividade não planejado: Frequent mechanical failures and lengthy liner changes halt the entire raw material preparation stage, custando milhares por hora em perda de produção.
Tamanho de feed inconsistente: Poorly controlled product size increases the load and wear on downstream ball mills, reducing their efficiency and increasing grinding media consumption.
Altos custos de substituição de peças de desgaste: Rapid degradation of hammers, rotores, and liners due to abrasive silica and alumina in raw mix leads to high spare part inventories and labor costs.

Is your current crushing solution delivering the reliability and costperton needed to remain competitive? The right primary crusher is not just a purchase; it's a strategic investment in plantwide stability.

2. VISÃO GERAL DO PRODUTO

The Gyratory Crusher is a primary crushing station engineered for the first stage of size reduction in cement raw material processing. It is designed to handle large feed blocks of quarried limestone, marl, or clay at high throughput rates with continuous operation.

Fluxo de Trabalho Operacional:
1. Dump trucks or feeders deliver large (até 1,5m) raw material blocks into the crusher’s deep, rugged feed hopper.
2. O eixo principal acionado excentricamente faz com que o manto gire, aplicando força compressiva contra os revestimentos côncavos estacionários.
3. Material is crushed by repeated compression cycles as it travels down through the chamber.
4. The crushed product discharges through the adjustable bottom shell setting, determining the final output size for conveyor transport to prehomogenization stockpiles.

Escopo de aplicação & Limitações:
Escopo: Ideal for highcapacity cement plants (2,500+ TPD) processing hard to mediumhard abrasive raw materials. It is the preferred solution for stationary primary crushing stations requiring continuous, reliable operation with minimal fines generation.
Limitações: Requer um investimento substancial de capital e uma fundação de concreto armado. Not suitable for mobile applications or for processing materials with high plasticity or moisture content that could cause packing.

3. RECURSOS PRINCIPAIS

Design de aranha patenteado | Base Técnica: Construção em aço forjado multibraço com vedação superior | Benefício Operacional: Distributes load evenly, prevents dust ingress, and provides secure mounting for mantle | Impacto do ROI: Prolonga os intervalos de manutenção em até 40%, reducing annual maintenance hours.

HydroSet System | Base Técnica: Hydraulic piston for main shaft positioning and overload protection | Benefício Operacional: Allows remote adjustment of crusher discharge setting and automatic clearing of blockages in under 60 segundos | Impacto do ROI: Minimizes downtime for product size changes and eliminates manual intervention for tramp iron events.

Concave Liner Profiles | Base Técnica: Computeroptimized chamber designs (padrão, grosseiro, multar) | Benefício Operacional: Maximizes throughput capacity and controls product gradation for optimal downstream mill feed | Impacto do ROI: Alcança até 15% higher throughput per installed horsepower compared to nonoptimized designs.

Integrated Main Shaft Lubrication | Base Técnica: Dedicated pressurized oil circulation system with temperature monitoring | Benefício Operacional: Ensures constant lubrication of bearings under extreme load, preventing seizure and catastrophic failure | Impacto do ROI: Protects core asset integrity; dados de campo mostram um >90% redução nas falhas relacionadas aos rolamentos.

Automated Wear Monitoring | Base Técnica: Laserbased concave liner thickness scanning system (opcional) | Benefício Operacional: Provides accurate, realtime data on liner wear without requiring entry into the crusher cavity | Impacto do ROI: Enables predictive liner scheduling, optimizing changeouts during planned stops and avoiding unexpected failures.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Maldito Mandíbula) | Solução de britador giratório | Vantagem (% melhoria) |
| : | : | : | : |
| Disponibilidade (%) | 85 90% | 94 96%| +6% (tempo de inatividade reduzido) |
| Custo Operacional ($/tonelada)| $0.50 $0.70| $0.35 $0.45| 30% (lower wear & poder) |
| Eficiência Energética (kWh/tonelada)| 0.8 1.2| 0.6 0.8| 25% (menor consumo de energia) |
| Vida útil do forro (Milhões de toneladas)| 0.8 1.2 Mt| 1.5 2.5 Mt| +80% (longer intervals) |
| Tamanho máximo de alimentação / Capacity Ratio| Lower ratio limits top size at high capacity| Higher ratio allows larger feed at same capacity| +35% (handles bigger blocks) |

5.ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: 2,000 – 10,000 toneladas métricas por hora (dependente de material).
Abertura de alimentação: Ranging from 800mm to 1500mm.
Potência do motor: 250 quilowatts – 800 kW dependendo do tamanho do modelo.
Faixa de ajuste da configuração de descarga: 100mm – 250mm via HydroSet system.
Main Shell & Forros: Estrutura principal em aço fundido de alta resistência; Manganese steel concave and mantle liners (1418% Mn).
Dimensões Físicas / Peso: Aprox.. altura: ~57m; peso: ~120 – 400 toneladas (including base frame).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; dusttight construction for indoor or outdoor installation.

6. CENÁRIOS DE APLICAÇÃO

LargeScale Integrated Cement Plant Expansion

Desafio:
A major producer expanding to a new 8,000 TPD line needed a primary crusher capable of processing highly abrasive limestone with minimal fines generation while guaranteeing >95% availability to protect their massive capital investment downstream.
Solução:
Installation of a heavyduty Gyratory Crusher with an optimized coarse crushing chamber profile.
Resultados:
Alcançado consistente <200mm product at a rate of over 2 ,200 tph . Disponibilidade da planta excedida 96 % no primeiro ano , with energy consumption measured at 0 .68 kWh / tonelada , directly supporting project ROI targets .

Modernization of Aging Crushing Circuit

Desafio:
An existing plant faced spiraling maintenance costs and weekly unplanned stoppages on its old primary jaw crushers , bottlenecking overall kiln feed capacity .
Solução:
Replacement of two parallel jaw crushers with a single , modern Gyratory Crusher , utilizing the existing feed system footprint .
Resultados:
O rendimento aumentou em 25 % while total connected power dropped by 180 kW . Os custos anuais de manutenção diminuíram em cerca de 45 % due to fewer wear parts and longer service cycles , justifying the capital expenditure within 22 meses .

7. CONSIDERAÇÕES COMERCIAIS

Equipment pricing is structured according to capacity rating , configuração da unidade ,and levelof factoryintegrated automation . We offer three core tiers :

• Nível I : Base Model – Includes core crusher , standard lubrication system ,e instrumentação básica . Suitablefor clientswith existing comprehensive maintenance teams .
• Nível II : Performance Model – Adds the HydroSet automation package , enhanced condition monitoring sensors ,and premium alloy liners . Recommendedfor maximum operational efficiency .
• Nível III : PlantReady Model – Fully integrated package including motor , VFD starter , automated lubrication cooling,and PLC control interface readyfor tiein .

Recursos opcionais :
• Automated wear monitoring system
• Special alloy liners forextreme abrasion
• Spare parts kits(preenchimento inicial)
• Remote diagnostic connectivity

Pacotes de serviços :
Comprehensive support agreements are available covering scheduled inspections predictive maintenance planning,e fornecimento prioritário de peças . Financing options including leasetoown structuresand project financing can be tailoredto alignwith your capital planning cycles .

8. Perguntas frequentes

1º trimestre : Isa gyratory crusher compatiblewith our existing secondary impact crushers ?
A1 : Sim . A gyratory cruser providesa controlled coarse product that isan ideal feedfor secondary crushing stages optimizing overall circuit balanceand reducing wear on downstream equipment .

2º trimestre : Whatisthe typical installation timelineand what site preparationisrequired ?
A2 : From foundation readinessto commissioning requires approximately 14 –18 weeks dependingon model size . Detailed civil engineering drawingsfor thereinforced concrete foundationare provided ;its designis criticalfor longterm stability .

3º trimestre : How doesthe operational cost comparetoa large jawcrusherover five years ?
A3 : Industry data indicatesgyratory crushers typically offer 20–30 % lower total costof ownership over five years primarily due t o superior energy efficiency longerwear part life andreduceddowntime .

4º trimestre : What trainingisprovidedfor our operationsand maintenance staff ?
A4 We provide comprehensive onsite training covering safe operation routine maintenance procedures troubleshooting guidelinesand detailed review ofthe lubricationand hydraulic systems .

Q5 Can this equipment handle stickyor highclay content materials ?
A5 While robust gyratorycrushers perform bestwith dryto moderately moist materials Very high claycontentcan leadto packingin lower sections We recommendmaterial testingand can discuss chamber designoptionsor prescreening solutionsif needed .

Q6 Whatisthe warranty structure?
A6 Our standard warranty covers manufacturing defectsin materialsand workmanshipfor one yearfrom commissioning Extended warranty coverage formajor componentsisavailableaspartofa service agreement .

Q7 How are spare parts logistics managed?
A7 We maintain regional inventory hubsfor criticalwear parts Consignment stock agreementscan be establishedat your site ensuring immediate availabilityof key componentslike mantles concavesand hydraulic parts