1. ABERTURA ACIONADA POR PAINPOINT

Are you managing gold ore processing operations where throughput bottlenecks and unpredictable maintenance costs are eroding your profit margins? The primary crushing stage often dictates the efficiency of your entire plant. Common challenges with suboptimal gold ore crushing equipment include:

Tempo de inatividade excessivo: Unplanned stoppages for liner changes or component failure directly reduce mill feed, custando milhares por hora em perda de produção.
Altos custos de abrasão: Gold ores, particularly those with high quartz content, rapidly wear crusher components, levando a frequentes, expensive replacements and inconsistent product sizing.
Inefficient Liberation: Inadequate or inconsistent particle size reduction from the primary stage can hinder downstream recovery in grinding and leaching circuits, leaving valuable gold locked in larger particles.
Ineficiência Energética: Older or poorly matched crushing equipment consumes excessive power per ton of ore processed, a significant and growing operational cost.

Is your current setup delivering the optimal balance of availability, wear cost per ton, and final product size for maximum gold recovery? The right primary crushing solution is not just about breaking rock; it's about securing the foundation of your plant's profitability.

2. VISÃO GERAL DO PRODUTO: PRIMARY JAW CRUSHER FOR GOLD ORE PROCESSING

This heavyduty jaw crusher is engineered as the first line of size reduction in hard rock gold mining operations. It is designed to accept runofmine (ROM) gold ore with a maximum feed size and reliably reduce it to a consistent discharge for conveyor transport to secondary crushing or stockpiling.

Fluxo de Trabalho Operacional:
1. ROM ore is fed via dump truck or loader into the vibrating grizzly feeder (VGF VGF), which bypasses subcrusher fines.
2. Oversize material is directed into the crusher’s fixed and moving jaw plates, where compressive force fractures the rock.
3. Crushed material exits through an adjustable discharge gap, determining the product’s top size.
4. The crushed product is conveyed for further processing.

Escopo de aplicação & Limitações:
Escopo: Ideal para britagem primária de materiais duros, minérios de ouro abrasivos (por exemplo, quartz veins). Suitable for both stationary plants and semimobile setups.
Limitações: Não projetado para molhado, sticky ores without proper feeder design. Maximum feed size is constrained by the crusher’s gape dimension.

3. RECURSOS PRINCIPAIS

HeavyDuty Frame Design | Base Técnica: Análise de Elementos Finitos (FEA) distribuição de tensão otimizada | Benefício Operacional: Eliminates frame fatigue cracking under cyclical loading from hard rock; garante integridade estrutural a longo prazo | Impacto do ROI: Prevents catastrophic frame failure and associated monthslong downtime, protegendo o investimento de capital

Manganese Steel Jaw Plates | Base Técnica: Workhardening alloy composition | Benefício Operacional: Plate surfaces harden upon impact, increasing service life in highly abrasive quartz environments | Impacto do ROI: Reduz a frequência de troca do revestimento em 3050%, lowering parts inventory costs and increasing crusher availability

Sistema de ajuste de alternância hidráulica | Base Técnica: Integrated hydraulic ram for tensioning & clearing | Benefício Operacional: Allows quick, safe adjustment of CSS (Configuração lateral fechada) for product control; enables automatic clearing of tramp metal/stalling events in minutes | Impacto do ROI: Minimizes nonproductive time for setting changes and blockages by up to 80% em comparação com sistemas de calços manuais

Grande abertura de alimentação & Câmara de britagem profunda | Base Técnica: Optimized geometry based on nip angle principles | Benefício Operacional: Accepts larger ROM feed blocks without bridging; provides longer wear life on jaw plates due to optimized motion | Impacto do ROI: Increases effective capacity and reduces precrushing or hammering requirements at the grizzly

Centralized Greasing System | Base Técnica: Automated lubrication points routed to a single station | Benefício Operacional: Ensures critical bearings receive consistent lubrication without operator exposure to moving parts | Impacto do ROI: Prolonga a vida útil do rolamento em até 40%, preventing costly unplanned bearing failures

BoltIn Toggle Seats | Base Técnica: Modular, replaceable seat design | Benefício Operacional: Worn toggle seats can be replaced without major welding or machining on the main frame | Impacto do ROI: Significantly reduces repair time and cost during major overhauls

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Média) | Esta solução de britador de mandíbula | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | 8590% | 9496%| +6% (Reduced downtime) |
| Wear Cost per Ton (Minério Abrasivo)| $0.45 $0.60/tonelada| $0.32 $0.38/tonelada| ~30% Reduction |
| Consumo de energia| 0.85 1.1 kWh/tonelada| 0.72 0.80 kWh/tonelada| ~20% Improvement |
| Tempo de ajuste CSS| 24 horas (manual)| 90% Mais rápido |

5. ESPECIFICAÇÕES TÉCNICAS

Modelo & Capacidade: JC1500HD; Throughput range of 650 – 1,100 mtph depending on feed gradation and CSS.
Abertura de alimentação: 59” x 78” (1500mm x 2000mm).
Requisitos de energia: 300 kW (400 HP) electric motor drive; standard softstart system included.
Especificações de materiais: Main frame fabricated from highstrength steel; jaw plates from premium grade manganese steel (1418%); shaft from forged alloy steel.
Dimensões Físicas: Aprox.. Comprimento: 10.5eu, Largura: 4.2eu, Altura: 4.8eu (including drive base).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 25°C a +50°C; dust sealing standard; optional highaltitude motor configurations available.

6. CENÁRIOS DE APLICAÇÃO

Hard Rock Underground Mine Portal Application

Challenge A midtier underground gold mine needed a reliable primary crusher at the portal to handle lumpy ROM ore (48”) with minimal fines generation for subsequent agglomeration before heap leaching.
Solution Installation of a JC1500HD jaw crusher with an integrated heavyduty apron feeder.
Results Achieved consistent 8” product at a rate of ~800 mtph with >95% availability over the first year. Fines generation (<1/2”) was maintained below target levels at <15%, optimizing agglomeration reagent use.

HighThroughput Open Pit Mine Expansion

Challenge An expanding openpit operation faced bottlenecks in their existing threestage plant due to an undersized primary crusher requiring frequent maintenance stops.
Solution Replacement with a highercapacity JC1500HD unit equipped with hydraulic toggle and automated greasing.
Results Plant throughput increased by an average of 18%. Maintenance hours on the primary station decreased by 35%, directly attributable to reduced liner changes and automated clearing functions.

7.CONSIDERAÇÕES COMERCIAIS

Equipment pricing is structured around configuration:

Camada Básica: Standard jaw crusher with motor drives and basic guarding.
Operational Tier (Mais Comum): Includes integrated motor base, hydraulic toggle adjustment system, centralized greasing, and starter panel.
Plant Integration Tier: Crusher supplied with matched vibrating grizzly feeder (VGF VGF), walkways/platforms, chute work, and PLC control interface.

Optional features include dust suppression systems specialized liners for specific ore geologies advanced condition monitoring sensors.

Service packages range from annual inspections to comprehensive fulllifecycle support contracts including planned outage management parts supply guarantees financing options include capital purchase leasetoown agreements tailored operating leases based on tonnes crushed.

8.Perguntas frequentes

Q What are my options if my gold ore has high clay content causing potential packing?
A We recommend pairing the crusher with a robust vibrating grizzly feeder VFG designed for scalping sticky material Optional hydraulic clearing prevents packingrelated stalls

Q How does this equipment integrate with my existing secondary cone crushers?
A The jaw crushers discharge setting CSS is easily adjusted via the hydraulic system to produce an optimal feed gradation for your specific secondary stage maximizing overall circuit efficiency

Q What is the expected lead time on critical wear parts like jaw plates?
A Based on our global distribution network standard manganese jaw plates are stocked regionally with guaranteed shipment within 72 hours under our premium service plan

Q Are there financing structures that align payment with my production output?
A Yes we offer tonnebased lease agreements where your monthly payment is partially indexed to actual tonnes processed sharing operational risk during rampup or lowergrade periods

P Que treinamento é fornecido para nossa equipe de manutenção?
A Commissioning includes comprehensive handson training covering daily inspections CSS adjustment tramp clearing procedures and planned liner change protocols