1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo suas margens de lucro agregadas ou de mineração? A britagem primária é um gargalo crítico, e a falha do equipamento aqui se espalha por toda a sua linha de processamento. Os principais desafios incluem:

Tempo de inatividade excessivo para manutenção: Frequent liner changes and unexpected mechanical repairs halt production, custando milhares por hora em perda de rendimento.
Alto consumo de peças de desgaste: Premature failure of jaw plates and cheek plates due to improper kinematics or material quality leads to unsustainable consumables spending.
Gradação inconsistente do produto: Unstable crushing chambers and poor feed control result in offspec product, increasing recirculation load and reducing saleable yield.
Aumento dos custos de energia: Inefficient crushers with high friction points and poor power utilization directly increase your kWhpertonne cost.
Preocupações com integridade estrutural: Fatigue cracks in the frame or pitman under highcycle loading pose serious safety risks and threaten catastrophic capital asset failure.

Is your primary crusher a source of constant concern rather than reliable productivity? The solution requires an engineered approach focused on durability, eficiência, e custo total de propriedade.

2. VISÃO GERAL DO PRODUTO

O JC5000 é um equipamento de alta capacidade, Britador de mandíbulas simples projetado para as aplicações de britagem primária mais exigentes em mineração, grandes operações em pedreiras, e processamento mineral industrial. Its robust design addresses the core need for continuous, reliable size reduction of hard, materiais abrasivos como granito, basalto, e minério de ferro.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Grande runofmine (ROM) o material é direcionado para as profundezas, câmara de britagem sem asfixia através de um alimentador vibratório (opcional).
2. Esmagamento Compressivo: The aggressively angled jaw plates and long stroke elliptical motion apply high compressive force, efficiently breaking large feed (até 1500 mm) to a targeted reduction ratio.
3. Descarga & Liberação: The hydraulic toggle release system allows for rapid clearing of tramp metal or uncrushable material, minimizing stallinduced downtime.
4. Transporte de Produto: Crushed material exits at the bottom discharge point onto the primary product conveyor for transport to secondary processing.

Escopo de aplicação & Limitações:
Escopo: Ideal for stationary primary crushing plants requiring throughputs from 750 para 1500 mtph. Suited for hard rock mining, produção agregada em grande escala, e processamento de escória.
Limitações: Not designed for mobile or semimobile applications due to its size and weight. Requires a substantial concrete foundation and significant plant infrastructure. Less optimal for recycling applications with high levels of rebar or mixed construction waste without extensive prescreening.

3. RECURSOS PRINCIPAIS

Geometria de Câmara Profunda | Base Técnica: Ângulo de aperto otimizado & longo golpe esmagador | Benefício Operacional: Maximizes size reduction per cycle, reduz a carga recirculante | Impacto do ROI: Higher throughput per operating hour lowers costpertonne

Estrutura fabricada para serviços pesados | Base Técnica: Análise de Elementos Finitos (FEA) optimized steel construction with reinforced stress points | Benefício Operacional: Eliminates frame fatigue under maximum load conditions over decades of service | Impacto do ROI: Protege o investimento de capital; prevents catastrophic failure and associated weeks of downtime

Sistema de acionamento hidrostático | Base Técnica: Acionamento hidráulico direto com bombas de deslocamento variável | Benefício Operacional: Fornece inicialização suave sob carga total, operação reversível para eliminar bloqueios, precise speed control | Impacto do ROI: Reduces mechanical stress on drivetrain components by up to 60%, extending bearing life

Sistema de placa de mandíbula QuickChange | Base Técnica: Wedgelocked mounting system with accessible frontside adjustment points | Benefício Operacional: Liner changes completed in hours instead of shifts by a standard maintenance crew | Impacto do ROI: Increases annual operating time by 100+ hours directly translating to revenue

Vedação de poeira integrada & Contenção| Base Técnica: Multistage labyrinth seals with positivepressure grease purging| Benefício Operacional: Effectively excludes abrasive dust from bearing housings and drive mechanisms| Impacto do ROI: Prolonga a vida útil crítica do rolamento em uma média de 40%, reduzindo o custo de estoque de peças de reposição

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Comparable Jaw Crushers) | Solução JC5000 | Vantagem (% Melhoria) |
| : | : | : | : |
| Vida útil do forro (Rocha Abrasiva)| 180 220 kTonne| 280 320 kTonne| +35% Vida útil prolongada |
| Tempo médio entre falhas (MTBF)| ~1.200 horas| Os dados de campo mostram >2,000 horas| +67% Confiabilidade aprimorada |
| Consumo de energia (kWh/Tonne)| Varia; muitas vezes ineficiente em carga parcial| Consistent efficiency across load range due to hydrostatic drive| Até 15% Reduction at optimal settings |
| Horas anuais de manutenção planejadas| ~250300 hours/year (incluindo. mudanças de revestimento)| ~160180 hours/year documented in case studies| ~35% Reduction in Labor & Tempo de inatividade |

5. ESPECIFICAÇÕES TÉCNICAS

Abertura de alimentação: 1500mm x 2.000 mm (59" x 79")
Tamanho máximo de alimentação: Até 1300 mm (51")
Configuração lateral fechada (CSS) Faixa: 180mm 350mm (7" 14")
Faixa de capacidade: 750 1500 mtph (dependente do material de alimentação & CSS)
Requisitos de energia da unidade: Dual electric motors totaling 450 kW /600 HP
Peso do britador (excluindo motor & unidades): Aproximadamente 125 Toneladas
Construção de moldura: Hightensile steel plate with stressrelieved welding
Jaw Plates Material Options: Manganese steel grades (14%,18%,21%), optional composite alloys
Faixa de temperatura operacional: 30°C a +45°C (22°F a +113°F) with standard lubrication systems

6. CENÁRIOS DE APLICAÇÃO

Planta de britagem primária de pedreira de granito | Desafio: A major aggregate producer faced liner changes every six weeks on their existing primary jaw crusher, causing 24hour production halts and high labor costs. Product gradation was inconsistent due to chamber wear.| Solução: Replaced the legacy unit with a JC5000 Jaw Crusher equipped with premium composite jaw plates.| Resultados: Liner life extended to over four months per set. Annual planned downtime reduced by approximately eight days. More consistent product gradation reduced secondary circuit recirculation by an estimated 15%.

Estação de britagem primária de minério de ferro | Desafio: An iron ore operation experienced frequent bearing failures on their primary crusher due to extreme dust ingress in an arid environment. Unscheduled stops were costing over $25k per hour in lost production.| Solução: Installation of a JC5000 Jaw Crusher featuring its integrated multistage dust sealing system.| Resultados: Bearing service intervals increased from six months to over sixteen months postinstallation. Two years of operation have passed without an unplanned crusherrelated stoppage.

7. CONSIDERAÇÕES COMERCIAIS

The JC5000 Jaw Crusher is offered as part of a comprehensive primary station solution.

Nível de preços do equipamento básico: Includes the crusher assembly with standard manganese jaw plates/cheek plates, hydraulic toggle adjustment & release system, motor mounts/sheaves.
Recursos opcionais & Atualizações: Composite/Alloy wear package; sistema automatizado de lubrificação com graxa; motor starter package/VFD controls; integrated condition monitoring sensors; custom discharge chute fabrication.
Pacotes de serviços disponíveis:

Suporte Platina: Inclui inspeções programadas, predictive maintenance analysis via telemetry data exchange from onboard sensors (~5year term).
Wear Parts Program: Guaranteed wear part pricing based on consumed tonnes processed (~3year term).
Comissionamento & Treinamento de Operadores: Onsite supervision during installation/startup.

Financing options are available through our partners including equipment leasing structures that allow you match payments directly against production output.

8.Perguntas frequentes

1.P:What is the lead time for delivery of a JC5000 Jaw Crusher?
A.Delivery times vary based on configuration but typically range from six months after final engineering approval due to its heavy fabrication requirements.

2.Q.Can we use our existing feeder,crusher foundation,e transportadores?
A.A detailed site audit is required.The JC5000 has specific foundation loading requirements but can often be adapted into existing flowsheets subject structural review.

3.Q.How does hydrostatic drive compare electrically?
A.The hydrostatic system provides superior torque control but may have marginally different power factor characteristics than traditional Vbelt drives requiring coordination during electrical design phase.

4.Q.What training do you provide?
A.Comprehensive training covering safe operation routine maintenance procedures troubleshooting guides provided both at commissioning via documentation/videos accessible online portal specific customer login credentials provided upon purchase agreement execution completion date set forth therein accordingly thereafter throughout ownership period thereof respectively thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereafter indefinitely thereaft