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 toda a linha de processamento. Os desafios comuns incluem:
Tempo de inatividade excessivo para trocas de revestimento: Traditional maintenance shutdowns for mantle and concave replacement can halt production for 2472 horas, costing tens of thousands in lost throughput.
Paradas não planejadas da Tramp Iron: Inadequate protection from noncrushable material leads to costly damage, requiring immediate intervention and component replacement.
Feed inconsistente & Distribuição do tamanho do produto: Fluctuating feed material characteristics cause chokefeeding issues or cavity flooding, reducing throughput and increasing power consumption per ton.
Alta operacional & Maintenance Labor Costs: Ajustes manuais frequentes, lubrication system monitoring, and component wear inspections demand significant skilled labor hours.

Is your operation seeking a primary crusher solution engineered to deliver maximum uptime, menor custo por tonelada, and predictable performance in the face of these challenges?

2. VISÃO GERAL DO PRODUTO

UM Triturador giratório é um serviço pesado, continuousduty primary crushing machine designed for highcapacity applications in largescale mining and aggregate operations. Its core mechanism involves a gyrating mantle within a stationary concave, creating a progressive crushing cavity that reduces runofmine ore or shot rock to a manageable size for downstream conveying and processing.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Largesized material is directed into the top of the crusher via dump trucks, carregadores, or a shovel.
2. Esmagamento Progressivo: The eccentrically driven mantle gyrates within the concave, applying compressive force to reduce material size with each cycle.
3. Descarga: Crushed product exits through the bottom of the crushing chamber (a abertura de descarga) onto a conveyor belt for transport to the next stage.

Escopo de aplicação: Ideal para alta tonelagem (1,500+ TPH) mineração de rocha dura (cobre, minério de ferro, ouro), grandes operações em pedreiras, and major industrial mineral processing plants requiring primary reduction of abrasive materials.

Limitações: Não adequado para operações de baixa capacidade (<500 TPH) devido ao alto custo de capital. Requires significant foundational support and vertical height. Less effective for recycling or asphalt crushing where jaw crushers or impactors may be preferred.

3. RECURSOS PRINCIPAIS

Design de aranha patenteado | Base Técnica: Multibraço, forged alloy steel construction with top shell attachment | Benefício Operacional: Distributes load evenly across the main shaft and bearings, providing exceptional stability under shock loading from large feed material | Impacto do ROI: Prolonga a vida útil do rolamento em até 40%, reducing major overhaul frequency and associated downtime costs.

Regulação de configuração automática integrada (RAS) Sistema | Base Técnica: Ajuste hidráulico com sensores de posição em tempo real | Benefício Operacional: Allows operators to adjust the crusher discharge setting remotely in minutes without stopping production, optimizing product size for changing downstream requirements | Impacto do ROI: Maintains optimal throughput and circuit efficiency; elimina 48 hours of manual adjustment labor per change.

Sistema de lubrificação com resfriadores duplos & Filtração | Base Técnica: Highflow circulation with temperature control and particulate filtration | Benefício Operacional: Ensures consistent bearing temperature under peak loads; removes metallic wear particles from oil | Impacto do ROI: Prevents thermalrelated bearing failures; dados de campo mostram um 25% reduction in lube oil degradation rate, reduzindo custos de consumíveis.

Manganese Steel Concave & Forros de manto | Base Técnica: Workhardening austenitic manganese steel castings | Benefício Operacional: Liners develop a hardened surface layer during operation that resists abrasion while maintaining core toughness against impact fractures | Impacto do ROI: Achieves industryleading wear life (measured in tons crushed), directly lowering costperton for wear components.

Tramp Iron Relief System | Base Técnica: Hydraulic cylinders support the main shaft assembly; pressure sensors detect uncrushable objects | Benefício Operacional: Automatically opens the discharge setting to release tramp iron, then returns to original setting without stopping the crusher drive motor | Impacto do ROI: Evita danos catastróficos; avoids unplanned downtime events that can exceed $100k in lost production per incident.

Chamber Profile Optimization | Base Técnica: Computermodeled nonchoking concave design with optimized nip angle | Benefício Operacional: Promotes firstpass reduction at the top of the chamber and ensures steady material flow without bridging or erratic power draw | Impacto do ROI: Entrega até 10% higher throughput compared to conventional profiles with identical motor power input.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Triturador giratório padrão da indústria | Nossa solução de britador giratório | Vantagem (% melhoria) |
| : | : | : | : |
| Disponibilidade (Agendado) | 9294% availability factor due to liner change downtime| 96%+ availability factor via quickchange liner systems & RAS| +34% horas mais produtivas anualmente |
| Consumo Específico de Energia| ~0,8 1.0 kWh/tonelada moída| ~0,7 0.85 kWh/tonne crushed via optimized kinematics| Até 15% lower energy cost per ton |
| Wear Life Concaves (Minério Abrasivo)| Life measured relative to baseline = 100%| Life measured relative to baseline = 130150%| +3050% intervalos de serviço mais longos |
| Hora de ajuste de CSS| Manual adjustment requires 48 hour shutdown| Remote hydraulic adjustment in <15 minutes via ASR system| ~98% less downtime for adjustments |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 1,500 acabar 12,000 toneladas por hora (TPH), depending on model size and feed material.
Potência do motor: Electric drive motors ranging from 450 kW para mais 1 PM (600 1,300 HP).
Abertura de alimentação: Tamanhos de abertura de 1,000 mm até 1,800 milímetros (aprox.. 40" para 72").
Faixa de ajuste da configuração de descarga: Normalmente de 125 mm para 250 milímetros (5" to10"), adjustable via hydraulic system.
Quadro Principal & Shell Material: Fabricated from hightensile strength steel plate; critical areas feature wearresistant liners.
Main Shaft Material: Forged from highstrength alloy steel with precision machining.
Faixa de temperatura operacional: Designed for ambient conditions from 40°C to +50°C (40°F a +122°F). Lube system includes heaters/coolers as required.
Contenção de poeira: Standard flanges provided for integration with dry dust suppression systems or water spray systems.

6. CENÁRIOS DE APLICAÇÃO

Expansão da mina de cobre em grande escala

Desafio: A Tier1 copper operation needed to increase primary crushing capacity by over 30% within existing footprint constraints while managing highly abrasive sulfide ore that caused rapid liner wear.
Solução: Implementation of two highcapacity Gyratory Crushers featuring our optimized chamber profile and premium manganese liners.
Resultados: Atingiu um rendimento sustentado de 8 ,500 TPH per crusher. Vida útil do revestimento aumentada em 35%, extending changeout cycles from 6 meses para acabar 8 meses. Overall plant availability improved by 2 .5%.

Major Granite Quarry Complex

Desafio: Unpredictable feed blockiness led to frequent cavity choking events in existing primary crushers , causing circuit stoppages , excessive energy spikes , and premature component stress .
Solução : Installation of a single heavyduty Gyratory Crusher equipped with an advanced nonchoking concave design and an automated tramp iron relief system .
Resultados : Eliminated unplanned choking events . Power draw stabilized , reducing specific energy consumption by 12%. Production yield of spec base material increased due t o more consistent product gradation .

7 . CONSIDERAÇÕES COMERCIAIS

Pricing tiers are structured according t o crusher size , capacidade ,and optional feature packages :
Base Model Range : Includes core crusher assembly , standard lubrication unit ,e instrumentação básica . Suitable f or standard duty cycles .
Pacote de desempenho : Adds Integrated ASR system , sensores avançados de monitoramento de condição ,and quickchange liner kits . Recommended f or operations prioritizing flexibility .
Premium Service Package : Bundles equipment with extended warranty coverage , predictive maintenance analytics software subscription,and guaranteed OEM spare parts delivery terms .

Financing Options include capital purchase ,contratos de arrendamento operacional,and throughputbased contracts where payments correlate directly w ith achieved production volume .

Service Packages range f rom basic technical support t o comprehensive onsite maintenance contracts managed b y factorytrained technicians .

8 . Perguntas frequentes

P : Can this gyratory crusher replace our existing primary jaw crusher without major modifications t o th e feed arrangement ?
UM : Embora possível,the taller vertical profile typically requires reassessment o f dump pocket design an d feeder height .Our engineering team provides detailed layout studies t o evaluate retrofit feasibility .

P : What i s th e typical installation an d commissioning timeline ?
A From delivery t o first ore,a standard project requires 8 12 semanas,following foundation readiness.This includes mechanical erection,lubrication an d hydraulic system commissioning,motor alignment,and noload/load testing .

Q How does th e automatic setting regulation impact final product shape ?
A The ASR adjusts th e closed side setting(CSS )t o control top size.It does not alter th e fundamental compressive breakage action,s o product shape(cubicidade )remains consistent w ith gyratory crushing characteristics .

Q Are wear parts interchangeable w ith other OEM g y r atory crushers ?
A No.Critical wear components like concaves,mantos,and spider arm guards are designed specifically f or our chamber geometry an d mounting systems.They are not dimensionally interchangeable,preserving designed performance an d safety .

Q What training i s provided f or our operations an d maintenance teams ?
A We provide comprehensive onsite training covering safe operation,procedimentos de manutenção de rotina,guias de solução de problemas,and specific instruction on using th e ASR an d condition monitoring systems .

Q What i s your lead time f o r critical spare parts ?
A Our global logistics network targets 9 5 % availability f or critical rotating assembly spares exstock fr om regional service centers.Nonstandard parts have defined manufacturing lead times provided upon request .