1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e a disponibilidade imprevisível estão minando a lucratividade do seu circuito de britagem primário? Para gerentes de fábrica e empreiteiros de engenharia, o estágio primário de britagem é um gargalo crítico onde as ineficiências se espalham por todo o processo posterior. Os principais desafios incluem:

Tempo de inatividade não programado: Premature failure of critical components like mainshafts or concaves leads to production halts costing tens of thousands per hour in lost throughput.
Custos excessivos de manutenção: Freqüente, laborintensive liner changes and unpredictable wear life consume maintenance budgets and divert skilled personnel from other critical tasks.
Tamanho do produto inconsistente: Poor feed distribution or worn crushing chambers yield an inconsistent feed for secondary circuits, reduzindo a eficiência geral da planta e a qualidade do produto final.
Alto consumo de energia: Inefficient crushing action and outdated drive systems result in unsustainable power draw, impactando diretamente seus resultados financeiros.
Flexibilidade de alimentação limitada: Inability to handle varying ore hardness or occasional tramp metal without causing significant damage.

How do you achieve higher throughput with greater reliability while controlling total cost of ownership? The answer lies in advanced gyratory crusher design focused on durability, intelligence, and efficiency.

2. VISÃO GERAL DO PRODUTO: TRITURADOR GIRATÓRIO PRIMÁRIO PESADO

This heavyduty primary gyratory crusher is engineered for the first stage of comminution in hightonnage mining and aggregate operations. It is designed to accept runofmine feed directly from haul trucks, delivering a consistent, coarse product to downstream conveying and processing systems.

Fluxo de Trabalho Operacional:
1. Aceitação de feed: Direct dump from haul trucks into the rugged feed hopper, guided by a onepiece spherical spider cap for optimal entry.
2. Ação Esmagadora: The eccentrically mounted mainshaft gyrates within the concave liners, applying compressive force to reduce large rock (often +1m) para um tamanho gerenciável.
3. Descarga do Produto: Crushed material exits through the discharge opening at the bottom of the crushing chamber, dictated by the selected crusher setting (CSS).

Escopo de aplicação & Limitações:
Escopo: Ideal para alta capacidade (5,000 15,000+ tph) primary crushing of abrasive hard rock (minério de ferro, minério de cobre, granito), calcário, and other minerals. Adequado para instalações fixas.
Limitações: Not designed for portable plants or lowtonnage operations (< 500 tph). Requer investimento de capital significativo e uma fundação de concreto armado. Less effective on clayrich or highly plastic materials that may cause packing.

3. RECURSOS PRINCIPAIS

Design côncavo patenteado | Base Técnica: Segmentado, alloyoptimized liner system with mechanical locking | Benefício Operacional: Reduz o tempo de inatividade de substituição em até 40% versus bolted designs; allows mixing liner profiles for optimal chamber geometry | Impacto do ROI: Lower labor costs per changeout and maximized liner utilization increase annual available crushing hours.

Sistema de controle inteligente integrado | Base Técnica: Sensores em tempo real monitorando pressão, temperatura, consumo de energia, e desgaste | Benefício Operacional: Provides predictive analytics for maintenance scheduling and alerts operators to abnormal conditions like bridging or overload | Impacto do ROI: Evita falhas catastróficas; enables conditionbased maintenance over scheduled intervals.

Liberação de Tramp Hydroset® & Ajuste CSS | Base Técnica: Hydraulic piston supporting the mainshaft for remote adjustment of the Closed Side Setting (CSS) | Benefício Operacional: Allows quick compensation for wear or product size changes without stopping the crusher; libera automaticamente ferro residual | Impacto do ROI: Mantém a consistência das especificações do produto; protects internal components from damage by uncrushables.

HighPrecision Spiral Bevel Gear & Pinhão | Base Técnica: Computermodeled gear geometry manufactured to AGMA 14 qualidade | Benefício Operacional: Ensures smooth power transmission with minimal vibration and noise; extends gear life significantly under hightorque loads | Impacto do ROI: Reduces risk of catastrophic drive system failure; lowers longterm spare parts inventory cost.

Lubrificação Automatizada Centralizada | Base Técnica: Programmable system delivering precise oil volumes to key bearings at set intervals | Benefício Operacional: Elimina erros de lubrificação manual; ensures optimal bearing temperature and longevity even in dusty environments | Impacto do ROI: Estende diretamente o tempo médio entre falhas (MTBF) for critical bearings; reduces lubricant consumption.

Robust Mainshaft & Head Center Design | Base Técnica: Forged from highstrength alloy steel with precision machining on bearing journals | Benefício Operacional: Provides exceptional resistance to bending fatigue and shock loads from oversized feed | Impacto do ROI: The core component's extended lifecycle defers major capital overhaul expenses for years.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nossa solução de britador giratório | Vantagem documentada |
| : | : | : | : |
| Tempo de troca do revestimento (Principal) | 48 72 horas | 24 36 hours with tooling package| Redução de aproximadamente 50% |
| Disponibilidade Operacional (Anual) | 92 94%| >96% (with Intelligent Control System)| +24 pontos percentuais |
| Consumo Específico de Energia (kWh/t) Varia de acordo com o material.| Linha de base = 100%| Redução média de 58% através de cinemática otimizada & eficiência de condução| ~7% improvement |
| Wear Life of Concaves (Minério Abrasivo) MTons/Set| Varies widely by ore.| Os dados de campo mostram uma melhoria consistente 1525% via material science & design.| ~20% increase |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Modelos configuráveis ​​de 3,000 acabar 15,000 toneladas métricas por hora (tph), dependendo do material de alimentação e da configuração do lado fechado.
Potência do motor: Opções de acionamento elétrico de 450 kW até 1,200 kW (600 1,600 HP). Dual pinion drives available for highest horsepower models.
Abertura de alimentação: Tamanhos de abertura de 1,300 mm para 1,800 milímetros (54" para 72").
Principais especificações de materiais: Main frame of fabricated hightensile steel; concaves in manganese steel or optional alloy composites; mainshaft forged from NiCrMo alloy steel.
Dimensões Físicas / Peso: Approximate total installed weight ranges from 400 toneladas para mais 800 tonnes depending on model size. Foundation forces are provided for detailed civil engineering.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 40°C a +50°C. Dust seals and pressurized housing options available for extreme environments.

6. CENÁRIOS DE APLICAÇÃO

Expansão da mina de cobre em grande escala

Challenge A tierone copper miner required a primary crusher solution for a new pit expansion capable of processing highly abrasive sulfide ore at >10,000 tph while minimizing planned downtime.
Solution Installation of a superduty gyratory crusher featuring our patented concave system and intelligent controls.
Results Achieved sustained throughput of 10,500 tph. Liner life increased by an average of 22%, reducing planned changeouts from three to two per year. The control system predicted a bearing anomaly months in advance, allowing planned intervention during a conveyor shutdown.

HighProduction Granite Quarry

Challenge An aggregate producer needed consistent (8 polegada) product size for their rail loadout facility but faced bottlenecks due to frequent maintenance on older equipment.
Solution Replacement with a midsize gyratory crusher equipped with Hydroset® automation.
Results CSS adjustments are now made remotely in minutes versus hours of manual work. Product consistency improved such that secondary cone crusher throughput increased by an estimated 9%. Annual maintenance hours decreased by 30%.

7. CONSIDERAÇÕES COMERCIAIS

Our gyratory crushers are offered under a transparent commercial framework designed for longterm partnership:

Níveis de preços de equipamentos: Pricing is modelspecific based on size/capacity. Standard packages include crusher assembly motor drive auxiliary lubrication unit basic controls foundation drawings
Recursos opcionais & Atualizações: Intelligent Control System premium wear material packages automated mantle positioning tool automated lubrication system special environmental sealing kits
Pacotes de serviços disponíveis
Basic Warranty covers defects in materials/workmanship
Extended Service Agreement includes scheduled inspections parts discounts technical support
Full Performance Contract guaranteed availability wear part consumption service crew support
Financing Options We work with leading industrial finance providers to offer competitive leasing longterm rental or purchase plans tailored to your capital expenditure cycles

8.Perguntas frequentes

Q What infrastructure is required prior installation?
A A reinforced concrete crusher foundation designed per our supplied load drawings is mandatory Access for heavy lift cranes during installation/maintenance must be considered Electrical substation capacity must match motor requirements

Q How does this integrate with our existing PLC/SCADA system?
A The crushers intelligent control system communicates via standard industrial protocols OPC UA Modbus TCP/IP providing key data points health status alarms It can function as standalone unit interface seamlessly

P O que é um prazo de entrega típico?
A Lead times vary by model complexity current manufacturing load Standard models typically have lead time months Custom configurations may require additional time Detailed schedule provided upon project initiation

Q Are training operator manuals provided?
A Yes comprehensive training program conducted at your site covers safe operation routine maintenance basic troubleshooting Detailed digital paper manuals parts books are supplied standard

Q Can you supply compatible downstream equipment conveyors bins?
A While we specialize primary crushing equipment we can provide interface specifications coordinate with preferred partners ensure complete circuit compatibility through project engineering phase