1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e a disponibilidade imprevisível estão minando a lucratividade do seu circuito de britagem primário? Plant managers and engineering contractors consistently face critical challenges in gyratory crusher operations that directly impact the bottom line.

Tempo de inatividade excessivo para manutenção: Scheduled mantle and concave changes can halt your entire primary feed line for days, custando milhares por hora em perda de produção.
Unplanned Stoppages from Feed Issues: Ponte, embalagem, or uneven feed distribution leads to costly, reactive interventions and potential damage to the crusher’s core components.
Aumento do consumo de energia: Inefficient crushing chambers and outdated drive systems consume disproportionate power without delivering optimal reduction, inflacionando despesas operacionais.
Tamanho do produto inconsistente & Capacidade: Wear over time alters the crushing cavity, leading to offspec product that stresses downstream processes and limits overall plant throughput.

How do you secure primary crushing reliability while controlling total cost of ownership? A solução requer equipamentos projetados não apenas para desempenho máximo, mas para sustentado, efficient operation with minimal operational disruption.

2. VISÃO GERAL DO PRODUTO

The modern highcapacity gyratory crusher is a stationary primary crushing solution designed for the most demanding mining and aggregate applications. It processes runofmine ore or large quarry rock into a consistent feed for secondary circuits.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Large dump trucks or loaders deposit material directly into the crusher’s robust feed hopper.
2. Ação Esmagadora: O manto giratório central comprime excentricamente o material contra os revestimentos côncavos estacionários, applying progressive compression to fracture the rock.
3. Descarga: Crushed product exits through the adjustable discharge opening at the bottom of the chamber, com tamanho determinado pela configuração fechada (CSS).

Escopo de aplicação: Ideal para alta tonelagem (1,500+ tph) mineração de rocha dura (cobre, minério de ferro, ouro), produção agregada em grande escala, and heavyduty industrial mineral processing.

Limitações: Não é adequado para operações de baixa tonelagem (<500 tph), highly abrasive but lowstrength materials where other crusher types may be more economical, or sites with extreme space constraints where a mobile primary might be necessary.

3. RECURSOS PRINCIPAIS

Design Inteligente de Câmara | Base Técnica: Ângulo de aperto otimizado e perfil da cavidade de britagem | Benefício Operacional: Delivers consistent reduction ratio with lower risk of bridging and reduced recirculating load | Impacto do ROI: Maximizes throughput yield per energy unit, reducing costperton

Sistema patenteado de retenção de revestimento | Base Técnica: Mechanically locked concave segments with backing material | Benefício Operacional: Elimina falhas no material de apoio e permite uma execução mais rápida, mudanças de revestimento mais seguras | Impacto do ROI: Reduz o tempo de inatividade planejado para manutenção em até 30%, aumentando as horas operacionais anuais disponíveis

Regulação de configuração automática integrada | Base Técnica: Hydraulic adjustment and monitoring of the main shaft position | Benefício Operacional: Allows operators to adjust CSS under load or remotely to maintain product size without stopping | Impacto do ROI: Maintains downstream process stability and final product specification, minimizing value loss

HighTorque Direct Drive System | Base Técnica: Lowspeed synchronous motor coupled directly to the eccentric | Benefício Operacional: Eliminates gear train inefficiencies, provides smooth startup under load, and reduces mechanical complexity | Impacto do ROI: Os dados de campo mostram 812% improvement in energy efficiency compared to traditional geared drives

Advanced Condition Monitoring Ports | Base Técnica: Integrated sensors for lubrication pressure/temperature, shaft position, and wear monitoring | Benefício Operacional: Enables predictive maintenance planning by providing realtime health data on critical systems | Impacto do ROI: Evita falhas catastróficas, extends component lifecycles, and optimizes maintenance scheduling

Opção de design sem aranha (for smaller models) | Base Técnica: Elimina a tradicional ponte de aranha na parte superior do britador | Benefício Operacional: Provides safer access for maintenance personnel and simplifies feed arrangement installation | Impacto do ROI: Reduces safety incident risk and shortens inspection times

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nossa solução de britador giratório | Vantagem documentada |
| : | : | : | : |
| Tempo de troca do revestimento| 4872 horas (full mantle/concave) | 3648 hours with patented system| 2533% mais rápido, increasing availability |
| Eficiência Energética (kWh/tonelada)| Varia de acordo com o material; linha de base estabelecida por projeto| Câmara otimizada & acionamento direto reduz o consumo| 812% melhoria in specific energy use |
| Tempo médio entre falhas (MTBF)| Dependent on maintenance rigor; typical major component intervals apply| Enhanced bearing design & filtration extend service life| Major component life extended by 1520% |
| Disponibilidade (Anual)| 9294% for wellmaintained units| Design focus on reliability & predictive monitoring targets >96%| Targets a 24 aumento de pontos percentuais, yielding significant extra tonnage |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 1,500 acabar 12,000 toneladas métricas por hora (tph), dependent on model selection, material de alimentação, e configuração lateral fechada.
Requisitos de potência do motor: Normalmente de 450 kW até 1 PM+; projetado para alta tensão (6.6kV 11kV) industrial power supply with softstart capability.
Especificações de materiais: Estrutura principal fabricada em aço de alta resistência; concaves and mantles available in premium manganese steel alloys or composite materials for specific abrasion/impact conditions.
Dimensões Físicas & Peso: Varia significativamente por modelo; largest units can exceed 10 meters in height and weigh over 500 toneladas. Foundation loading specifications are provided per project.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 40°C a +50°C. Os sistemas de vedação contra poeira são padrão; optional kits are available for extreme environments.

6. CENÁRIOS DE APLICAÇÃO

Expansão da mina de cobre em grande escala

Desafio: An existing mine expansion required a new primary crusher capable of handling 6,000 tph of abrasive copper porphyry ore while fitting within constrained space in an expanded pit perimeter.
Solução: Installation of a compact topservice gyratory crusher with a spiderless design.
Resultados: Achieved design throughput within three months of commissioning. The simplified access reduced planned service stops by an average of 18 hours per event compared to the site's older units.

HighProduction Granite Aggregate Quarry

Desafio: A coastal quarry needed to increase finished base material production but faced prohibitive energy costs and excessive wear on its existing primary jaw crusher when processing hard granite.
Solução: Replacement with an energyfocused gyratory crusher featuring an intelligent chamber profile and direct drive system.
Resultados: A produtividade da planta aumentou em 22%. Specific energy consumption (kWh/tonelada) decreased by 9%, resulting in a calculated payback period of under three years based on energy savings alone.

7. CONSIDERAÇÕES COMERCIAIS

Os britadores giratórios representam um investimento de capital significativo, adaptado precisamente aos requisitos do projeto.

Níveis de preços: O custo de capital é determinado principalmente pelo tamanho/capacidade (por exemplo, 4265”, 5475”, 6089” models), drive system selection (direct vs. geared), and level of automation integration.
Recursos opcionais & Pacotes: Common options include advanced lubrication filtration systems automated wear part measurement devices remote control interfaces specific liner material grades
Pacotes de serviços: Comprehensive Life Cycle Service contracts are available covering scheduled maintenance parts supply (with guaranteed inventory holding) predictive monitoring support field service engineering
Opções de financiamento: We work with major industrial financing partners to offer flexible solutions including capital lease operating lease or projectbased financing structures aligned with your mine plan or project cash flow

8. Perguntas frequentes

1º trimestre: Este britador giratório é compatível com nosso sistema de controle de planta existente??
A1 Most modern units come equipped with industrystandard communication protocols Modbus TCP/IP OPC UA allowing integration into most supervisory control SCADA systems Interface documentation is provided for your engineering team

Q2 Qual é o impacto operacional esperado durante a instalação?
A2 Installation requires significant planning foundation work mechanical erection electrical connection Typical greenfield installation timelines range from four six months Brownfield replacements require a coordinated plant shutdown usually four eight weeks depending on complexity

Q3 How does this equipment improve our overall costperton metric?
A3 The improvement comes from multiple factors higher availability reduces fixed cost allocation per ton lower energy consumption reduces variable costs extended liner life decreases consumable costs Combined these deliver a measurable reduction in total operating cost over the equipment lifecycle

Q4 Quais termos comerciais são padrão?
A4 Equipment sales typically follow FCA Incoterms at our manufacturing facility Longerterm service agreements have defined terms scope pricing schedules based on annual operating hours Support is quoted separately based on required response times parts coverage levels

Q5 Que treinamento é fornecido para nossas equipes de manutenção operacional?
A5 Comprehensive training is included covering normal operation emergency procedures routine checks major component replacement This includes both classroom instruction handson training during commissioning Documentation includes detailed operation maintenance manuals parts lists