1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e a disponibilidade imprevisível estão minando a lucratividade do seu circuito de britagem primário? Key challenges in primary gyratory crusher operation directly impact your bottom line:
Tempo de inatividade excessivo para manutenção: Traditional spider arm and top shell designs require complex, timeconsuming procedures for wear part replacement, leading to production losses of several days.
Paradas não planejadas da Tramp Iron: Inadequate protection mechanisms can result in catastrophic damage from uncrushable material, with repair costs exceeding hundreds of thousands and causing extended outages.
Taxa de transferência inconsistente & Product Gradation: Worn or poorly designed crushing chambers fail to maintain optimal feed acceptance and product size control, bottlenecking downstream processes and reducing final product yield.
Alto Consumo de Energia por Tonelada: Inefficient crushing action and excessive friction from outdated mechanical designs lead to unsustainable power costs, a major operational expenditure.

Is your operation equipped to overcome these challenges? The solution lies in a modern gyratory crusher engineered for reliability, eficiência, and lower total cost of ownership.

2. VISÃO GERAL DO PRODUTO: TRITURADOR GIRATÓRIO

A gyratory crusher is a primary compression crusher central to hightonnage mining and aggregate operations. Utiliza uma casca cônica fixa (côncavo) and a gyrating mantle mounted on an eccentric shaft to reduce large runofmine (ROM) feed material down to a conveyable size.

Fluxo de Trabalho Operacional:
1. Aceitação de feed: ROM material is fed into the top of the crusher via dump trucks, carregadores, or a primary feeder, entering the gap between the mantle and concave.
2. Esmagamento Compressivo: O manto gira dentro do côncavo, applying compressive force to the rock particles against the stationary liners.
3. Redução Progressiva: Material is crushed continuously as it moves down through the chamber due to gravity and the crushing action.
4. Descarga: Crushed product exits at the bottom through the discharge opening (OSS), where it is transported via conveyor for secondary processing.

Escopo de aplicação & Limitações:
Escopo: Ideal para alta capacidade (1,000+ TPH) primary crushing of hard, minérios abrasivos (minério de ferro, minério de cobre) e grande feed agregado. Suited for stationary plant installations.
Limitações: Not designed for recycled concrete/asphalt or lowtonnage applications. Requires significant capital investment and a robust foundation. Feed size must be controlled within design parameters.

3. RECURSOS PRINCIPAIS

Patented Top Service Design | Base Técnica: Simplified mechanical access from above | Benefício Operacional: Enables liner changes and maintenance in 2448 hours versus 57 dias | Impacto do ROI: Reduces planned downtime by over 60%, aumentando o tempo de produção anual disponível

Integrated Automatic Tramp Release System | Base Técnica: Cilindros hidráulicos suportam o eixo principal | Benefício Operacional: Automatically lowers the main shaft to pass tramp iron, then resets without stopping | Impacto do ROI: Eliminates costly damage from uncrushables; prevents an average of 35 days of unplanned downtime annually

Optimized Crushing Chamber Profiles | Base Técnica: Computermodeled kinematics and wear simulation | Benefício Operacional: Maintains consistent feed acceptance and product gradation throughout liner life | Impacto do ROI: Improves overall circuit throughput stability by 58% and extends liner service life by 1525%

HighPower Drive & Robust Eccentric Assembly | Base Técnica: Hightorque motor coupled with a forged alloy steel eccentric | Benefício Operacional: Delivers consistent crushing force under peak loading conditions with minimal vibration | Impacto do ROI: Provides higher availability (>94%) and reduces stressinduced component failures

Sistema de lubrificação automatizado centralizado | Base Técnica: Programmable PLCcontrolled lubrication to all critical bearings | Benefício Operacional: Ensures optimal bearing temperature and health; provides diagnostic alerts | Impacto do ROI: Prolonga a vida útil do rolamento em até 30% and prevents lubricationrelated stoppages

StateoftheArt Control System (ICS) | Base Técnica: Realtime monitoring of power draw, pressão, temperatura, and cavity level | Benefício Operacional: Allows operators to optimize performance and receive predictive maintenance alerts | Impacto do ROI: Increases operational efficiency by 35% through precise control; enables conditionbased maintenance planning

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Older Gyratory Designs) | Modern Gyratory Crusher Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Planned Maintenance Time (Spider Arm/Liners) | 120 168 horas | 48 72 hours with Top Service Design| 60% Redução |
| Disponibilidade Mecânica (Anual) | 88 91%| >94% (média de campo documentada)| 36% Aumentar |
| Liner Utilization (Tonnes/Liner KG)| Linha de base| Optimized chamber design & materiais| 1525% Melhoria|
| Consumo de energia (kWh/tonelada)| Linha de base| Efficient drive & chamber kinematics| 510% Redução |
| Tramp Iron Damage Events / Ano| 0.5 1 event (média.)| Nearzero with automatic system| >95% Redução |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 1,500 acabar 12,000 toneladas por hora (TPH), depending on model chamber selection and feed material.
Potência do motor: Heavyduty squirrel cage induction motors ranging from 450 kW para mais 1 PM.
Abertura de alimentação: Tamanhos de abertura de 1,000 mm up to 1,800 mm for handling large ROM feed.
Quadro Principal & Côncavo: Fabricated highstrength steel main frame; concaves available in manganese steel or composite alloy designs for specific abrasion/impact conditions.
Dimensões & Peso: Significant footprint; approximate installed weight ranges from 250 tonnes for smaller models to over 800 tonnes for largest units.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 40°C a +50°C com sistemas de lubrificação apropriados. A vedação contra poeira é padrão.

6. CENÁRIOS DE APLICAÇÃO

Expansão da mina de cobre em grande escala

Desafio: Uma operação de cobre de primeira linha precisava aumentar o rendimento da planta em 25%. Their existing primary gyratory was a bottleneck with frequent liner change downtime exceeding one week.
Solução: Installation of a new highcapacity gyratory crusher featuring top service design and an automated tramp release system.
Resultados: Achieved sustained throughput increase of 28%. Planned maintenance time reduced by approximately five days per event. Zero unplanned downtime due to tramp metal in the first two years of operation.

Atualização de pedreira de agregado de granito

Desafio: A quarry producing railway ballast faced inconsistent product gradation as liners wore, leading to excessive recirculating load in their secondary circuit.
Solução: Implementation of a midrange gyratory crusher with computeroptimized crushing chamber profiles linked to an advanced control system (ICS).
Resultados: Product gradation remained within specification throughout >90% of liner life. Recirculating load decreased by an average of 15%, reducing energy consumption in the secondary cone crushers.

7. CONSIDERAÇÕES COMERCIAIS

Níveis de preços: Capital cost varies significantly based on size/capacity:
MidRange Units (6,000 TPH): For major greenfield or expansion projects in bulk mining.

Recursos opcionais & Atualizações: Sistemas avançados de monitoramento de desgaste; specialized liner alloys for specific ore types; upgraded filtration systems for extreme environments; remote diagnostics connectivity.

Pacotes de serviços: Tiered offerings include:
Garantia Básica & Parts Support
Planned Maintenance Agreements with guaranteed parts supply
FullPerformance Contracts covering parts AND labor with availability guarantees

Opções de financiamento: Projectspecific financing through manufactureraffiliated programs can include leasetoown structures or extended payment terms aligned with project rampup milestones.

8. Perguntas frequentes

1º trimestre: Is this equipment compatible with our existing primary feeding system?
A compatibility review is standard during project engineering analysis based on your feeder type capacity hopper design We provide detailed interface specifications

Q2 Qual é o impacto esperado no consumo geral de energia da nossa planta?
Field data shows modern drives optimized chambers can reduce specific energy kWh tonne crushed by This contributes directly lower operating costs

Q3 Are there financing options available beyond standard purchase?
Yes we offer several commercial structures including operating leases long term payment plans tailored large capital projects Consult our commercial team details

Q4 How does implementation typically affect ongoing personnel training?
We provide comprehensive onsite operator maintenance training documentation ensure your team achieves proficiency safe efficient operation quickly minimize transition disruption

Q5 What are lead times typical delivery installation schedule?
Lead times vary model specification current demand but generally range months Detailed project schedule developed during pre order engineering phase account site preparation logistics commissioning