1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e a disponibilidade imprevisível estão minando a lucratividade do seu circuito de britagem primário? Key challenges in gyratory crusher operations directly impact your bottom line:
Tempo de inatividade não programado: Bearing failures or mainshaft issues can halt your entire processing line for days, custando centenas de milhares em perda de produção.
Altos custos de manutenção: Freqüente, laborintensive liner changes and component wear consume both maintenance budgets and valuable operating hours.
Taxa de transferência inconsistente & Tamanho do produto: Flutuações no material de alimentação ou desgaste ao longo do tempo levam a produtos fora das especificações, creating bottlenecks and reducing downstream efficiency.
Consumo excessivo de energia: Older or inefficient designs draw more power per ton processed, a fixed cost that significantly impacts operating margins.

Como você consegue maior rendimento com maior confiabilidade e ao mesmo tempo controla o custo total de propriedade? The solution requires a crusher engineered not just for peak performance, mas para sustentado, predictable operation under the most demanding conditions.

2. VISÃO GERAL DO PRODUTO

The Custom Gyratory Crusher is a heavyduty, primary crushing machine designed for hightonnage, continuous operation in largescale mining and aggregate production. It performs compressive crushing via a gyrating mantle within a concave hopper.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Runofmine (ROM) ore or large quarry rock is directly dumped into the top of the crusher’s deep, nonchoking concave.
2. Esmagamento Compressivo: The eccentrically gyrating mantle repeatedly advances and recedes from the concave liners, applying massive compressive force to reduce material size.
3. Controle de configuração de descarga: The crushed product exits through the adjustable bottom setting (ABS), com tamanho determinado pela configuração fechada (CSS) between the mantle and concave at their lowest point.
4. Descarga & Transporte: Sized material is discharged onto a primary conveyor for transport to the next stage of processing.

Escopo de aplicação: Ideal for primary crushing of abrasive hard rock (minério de ferro, minério de cobre, granito), hightonnage aggregate production, and heap leach applications requiring coarse product. Not recommended for lowtonnage operations, soft or nonabrasive materials only, or sites with severe space constraints where a jaw crusher may be more appropriate.

3. RECURSOS PRINCIPAIS

Patented QS™ Quill Shaft System | Base Técnica: Isolated eccentric motion with hydrostatic lubrication | Benefício Operacional: Eliminates metaltometal contact in the eccentric assembly, drastically reducing wear and risk of catastrophic failure | Impacto do ROI: Os dados de campo aparecem até 40% longer service intervals for the eccentric system and a documented 60% reduction in related unscheduled downtime.

INTEGRAL™ Concave & Mantle Liner System | Base Técnica: Interlocking alloy segments with optimized chamber geometry | Benefício Operacional: Provides more consistent product gradation throughout liner life and reduces changeout time by up to 30% compared to traditional designs | Impacto do ROI: Lower liner cost per ton crushed and increased crusher availability for production.

SMARTSENSE™ Bearing Monitoring | Base Técnica: Integrated vibration, temperatura, and pressure sensors on critical bearings | Benefício Operacional: Your maintenance team receives realtime health data and predictive alerts, enabling conditionbased maintenance planning | Impacto do ROI: Evita falhas inesperadas nos rolamentos, protects against secondary damage to shafts and housings.

HYDROSET® PLUS Chamber Clearing & Ajuste | Base Técnica: Dualfunction hydraulic ram system for setting adjustment and automated chamber clearing | Benefício Operacional: Operators can adjust CSS under load or clear a stalled cavity remotely in minutes from the control room | Impacto do ROI: Maximiza o tempo de atividade; eliminates hours of manual clearing efforts and associated safety risks.

HEAVYDUTY Spiral Bevel Gear & Pinhão | Base Técnica: Forged alloy steel gears with computeroptimized tooth profile | Benefício Operacional: Transmits high torque smoothly with minimal noise and vibration, even under uneven loading conditions | Impacto do ROI: Industry testing demonstrates a typical service life extension of 25% over standard gear sets under comparable duty cycles.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Média padrão da indústria | Custom Gyratory Crusher Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de execução agendado) | 9294% | 96.5%+ | +35% |
| Tempo de troca do revestimento (Horas) | 2436 horas | 1620 horas | ~40% mais rápido |
| Consumo de energia (kWh/t) Baseline Ore| 0.8 1.2 kWh/t| 0.65 0.9 kWh/t| Até 20% Mais eficiente |
| Tempo médio entre falhas (MTBF) Eccentric System| ~12,000 hrs| >18,000 horas| +50% Confiabilidade |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Modelos configuráveis ​​de 2,000 tph para mais 10,000 tph.
Abertura de alimentação: De 1,070 milímetros (42”) até 1,520 milímetros (60”) dependente do modelo.
Requisito de potência do motor: Tipicamente 375 kW para 750 kW (500 HP para 1000 HP+), fornecido em 6.6 kV or as required.
Peso total: Ranges from approximately 150 toneladas para mais 400 toneladas para configurações maiores.
Principais especificações de materiais:
Quadro Principal & Concha superior: Highstrength fabricated steel with stressrelieving treatment.
Mainshaft: Forged from highalloy nickelchromiummolybdenum steel.
Côncavo & Forros de manto: Ligas de aço manganês (14%18% Mn), optional chromewhite iron or composite alloys for specific abrasion/corrosion applications.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 40°C a +50°C. Dust seals rated for harsh environments; sistemas opcionais de aquecimento/resfriamento disponíveis.

6. CENÁRIOS DE APLICAÇÃO

Expansão da mina de cobre em grande escala

Desafio: A planned expansion required a primary crusher capable of handling an additional 8 million tonnes per annum of highly abrasive porphyry ore without increasing footprint or headcount disproportionately.
Solução: Installation of one Custom Gyratory Crusher with INTEGRAL™ liners configured for coarse crushing ahead of SAG mills.
Resultados: Atingiu um rendimento sustentado de 4,500 tph at a consistent P80 of 150mm. A vida útil do revestimento aumentou em média 15%, contributing to a calculated total cost per tonne reduction of approximately $0.12 across the crushing circuit.

Pedreira de granito de alta produção

Desafio: Frequent downtime due to tramp metal events causing damage and lengthy cavity clearing procedures was limiting annual output targets.
Solução: Implementation of our gyratory crusher equipped with the HYDROSET® PLUS system and SMARTSENSE™ monitoring.
Resultados: Cavity clearing events reduced from an average operational delay of 8 horas para menos 45 minutes per incident. Annual plant availability increased by over 300 horas (12+ dias), directly translating to an additional ~450k tonnes crushed per year within existing shifts.

7 CONSIDERAÇÕES COMERCIAIS

Equipment pricing is structured into three primary tiers based on size/capacity (CGC50 Series, CGC60 Series, CGC72 Series) with base configurations including core drive system controls motor starter lubrication unit

Recursos opcionais incluem:
Advanced automation packages remote diagnostic telemetry special alloy liner packages dust suppression ring

Pacotes de serviços são oferecidos separadamente:
Bronze (Garantia Básica) Prata (Planned Inspection & Parts Discount) Ouro (FullService Contract including scheduled labor parts predictive monitoring)

Financing options are available through our partners including capital lease operating lease project financing terms typically structured over years

Perguntas frequentes

Qual é o cronograma típico de instalação?
From delivery onsite mechanical erection electrical connection commissioning full operation typically requires weeks depending on foundation readiness site support

How does this crusher integrate with my existing control system?
The crushers PLC is designed for interoperability providing standard communication protocols Modbus TCP/IP Profibus We supply full interface documentation

Can you provide wear part cost guarantees?
Yes we offer guaranteed maximum wear part cost per tonne contracts based on your specific feed material analysis providing predictable longterm budgeting

Quais são as suas condições de pagamento?
Standard commercial terms involve progress payments tied key milestones delivery acceptance Final payment due upon successful completion performance run

Você oferece treinamento de operador?
Comprehensive training is included covering safe operation routine maintenance troubleshooting conducted both at commissioning at your facility