1. ABERTURA ACIONADA POR PAINPOINT

Are escalating operational costs and unpredictable downtime eroding your primary crushing circuit's profitability? Para gerentes de fábrica e empreiteiros de engenharia, the primary crushing stage is a critical bottleneck where failures have cascading, costly consequences. Os desafios comuns incluem:

Tempo de inatividade não programado: Bearing failures or unexpected wear part changes can halt your entire processing line, costing tens of thousands per hour in lost production.
Altos custos de manutenção: Freqüente, laborintensive liner changes and component overhauls consume both budget and valuable maintenance crew hours.
Taxa de transferência inconsistente & Tamanho do produto: Fluctuations in feed material or equipment limitations lead to poor fragmentation, placing undue stress on downstream crushers and mills, reducing their efficiency and lifespan.
Consumo excessivo de energia: An inefficiently operating primary crusher is one of the single largest power draws on site, directly impacting your costperton metric.

Is your operation equipped with a primary crusher designed to mitigate these risks through robust engineering and intelligent design? A reliable gyratory crusher is not merely an expense but a strategic investment in plantwide stability and throughput.

2. VISÃO GERAL DO PRODUTO: TRITURADOR GIRATÓRIO

A gyratory crusher is a largescale, stationary primary crushing machine central to hard rock mining and hightonnage aggregate operations. It functions by utilizing a gyrating mantle within a concave hopper to compress and fragment large feed material (muitas vezes excedendo 1 meter in size) into a smaller, consistent product for secondary processing.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Runofmine (ROM) ore or large quarry rock is directed into the top of the crusher's deep, rugged concave.
2. Esmagamento Compressivo: The eccentrically driven mantle gyrates within the stationary concave, repeatedly compressing the material against the chamber walls.
3. Redução Progressiva: Material is crushed continuously as it moves down through the chamber due to gravity and the crushing action.
4. Descarga: The nowreduced material exits through the discharge opening at the bottom, with size controlled by the closedside setting (CSS).

Escopo de aplicação & Limitações:
Escopo: Ideal para alta capacidade (1,000+ TPH) primary crushing applications involving abrasive ores (cobre, ouro, ferro) and hard rock aggregates. Excels in handling slabby material and provides continuous crushing action.
Limitações: Higher initial capital cost compared to large jaw crushers. Requires a substantial foundation and elevated installation for discharge conveyor access. Not suitable for portable plants or lowtonnage operations.

3. RECURSOS PRINCIPAIS

Patented Concave Design | Base Técnica: Segmentado, alloyoptimized liners with enhanced chamber geometry | Benefício Operacional: Extends liner service life by up to 30%, promotes better nip angle for more efficient crushing | Impacto do ROI: Reduces liner inventory costs and changeout frequency, lowering cost per ton crushed.

Integrated Intelligent Control System | Base Técnica: Realtime monitoring of power draw, pressão, and CSS with automated adjustment protocols | Benefício Operacional: Prevents overload conditions, optimizes throughput dynamically, provides predictive maintenance alerts | Impacto do ROI: Maximizes energy efficiency by 515% and prevents catastrophic damage from tramp metal or feed surges.

Spiderless Top Shell Design | Base Técnica: Eliminates traditional spider arms through a reinforced singlepiece top shell | Benefício Operacional: Removes a major wear point, simplifies maintenance access for mantle changeouts by up to 50% mais rápido | Impacto do ROI: Directly reduces planned maintenance downtime hours, increasing annual available operating time.

HighCapacity Main Shaft & Conjunto de rolamento | Base Técnica: Forged alloy steel shaft supported by heavyduty radial and thrust bearings with advanced lubrication circuits | Benefício Operacional: Provides unmatched durability under peak load conditions; bearing temperature monitoring ensures reliability | Impacto do ROI: Eliminates unplanned failures related to the core drivetrain—the most costly source of extended downtime.

Automated Wear Part Measurement | Base Técnica: Laserbased cavity profiling system integrated into control platform | Benefício Operacional: Provides accurate, operatorsafe measurement of mantle and concave wear without manual entry | Impacto do ROI: Enables optimal liner change scheduling based on actual wear data, preventing premature changes or runtofailure risks.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nossa solução de britador giratório | Vantagem documentada |
| : | : | : | : |
| Vida útil do forro (Minério Abrasivo) | ~6 Months Average Life Cycle| 8+ Months Demonstrated Life Cycle| +33% Melhoria |
| Eficiência Energética (kWh/tonelada) Linha de base = 100%| ~0.85 1.1 kWh/tonelada| Optimized range of 0.75 0.95 kWh/tonelada| Até 15% Redução |
| Mantle ChangeOut Time (Crew Hours)| 24 36 Hours Typical Downtime| 25% Mais rápido |
| Annual Availability Target (Excluding Planned Stops)| ~92 94% Availability Goal| >96% FieldVerified Availability| +24% Uptime Increase |

5. ESPECIFICAÇÕES TÉCNICAS

Gama de modelos & Capacidade: Available in multiple sizes with nominal capacities from 1,200 acabar 10,000 toneladas por hora, based on specific ore characteristics and closedside setting.
Requisitos de energia: Motores de acionamento principal de 300 kW até 800+ kW, tailored to duty requirements; complete Ehouses available.
Especificações de materiais: Manto & concaves manufactured from proprietary Manganese steel alloys; main shaft from highstrength forged steel; base frame constructed from heavyduty fabricated steel plate.
Dimensões Físicas & Peso: Varia significativamente por modelo; largest units can exceed 10 meters in height with installed weights over 500 toneladas. Foundation loading data provided for engineering.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 40°C a +50°C. Dust sealing systems are standard; optional kits available for extreme arctic or tropical environments.

6. CENÁRIOS DE APLICAÇÃO

Expansão da mina de cobre em grande escala

Desafio: A Tier1 copper operation needed to increase primary crushed throughput by 25% without expanding their truck dump pocket or adding building footprint due to space constraints.
Solução: Implementation of a highcapacity gyratory crusher with an optimized stroke and higher motor power within an existing footprint replacement project.
Resultados: Achieved a sustained throughput increase of 28%. The intelligent control system managed variable ore hardness effectively, protecting downstream conveyors while meeting new tonnage targets without major structural modifications.

Granite Aggregate Quarry Modernization

Desafio: A major quarry faced excessive downtime every 912 months for complete spider arm replacement on their aging primary gyratory crusher—a process taking over two weeks.
Solução: Replacement with a modern spiderless top shell design gyratory crusher model sized for their future reserves.
Resultados: Eliminated spiderrelated maintenance entirely. Planned mantle changes are now completed in under two days instead of two weeks for major overhauls—a direct recovery of over ten days of production annually while reducing labor costs.

7. CONSIDERAÇÕES COMERCIAIS

Our gyratory crushers are offered as engineered capital solutions with clear total cost of ownership benefits.

Níveis de preços: Configured based on size/capacity (Dever Padrão, Serviço Pesado, Super Heavy Duty) with corresponding structural reinforcements and component ratings.
Recursos opcionais & Atualizações: Key options include advanced lubrication filtration systems fully automated setting adjustment cylinders remote diagnostic telemetry packages specialized liner alloys for specific abrasion/corrosion profiles
Pacotes de serviços: Comprehensive support plans are available including scheduled inspection programs guaranteed parts availability programs (por exemplo, nextflightout spares) dedicated technical support hotline
Opções de financiamento: We work with international financing partners to offer flexible solutions including capital lease operating lease project financing structures tailored for mining assets

8.Perguntas frequentes

Q What level of foundation engineering is required?
A These are heavy dynamic load machines Detailed geotechnical analysis is required We provide full dynamic load data specifications early in project discussions enabling your civil engineers to design an appropriate foundation

Q How does this integrate with our existing PLC/SCADA system?
A The crushers intelligent control system communicates via industrystandard protocols Modbus TCP/IP Profinet It can function as a standalone unit or be fully integrated into your plants central control room

Q What is the typical lead time from order placement commissioning?
A Lead times vary by model complexity but generally range between months This includes manufacturing testing disassembly shipping reassembly onsite supervision We provide detailed project milestone schedules upon quotation

P São oferecidas garantias de desempenho?
A Yes we offer performance guarantees based on mutually agreed test protocols postinstallation These typically cover throughput capacity product size distribution PSD power consumption under defined feed conditions

Q What training is provided operators maintenance staff?
A We provide comprehensive onsite training covering normal operation emergency procedures routine maintenance tasks troubleshooting Training manuals video libraries are supplied as standard

Q Can you supply all auxiliary equipment conveyors dust suppression etc
A We act as main supplier can coordinate supply installation all associated auxiliary equipment through our network vetted partners providing singlepoint responsibility turnkey projects