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 gyratory crusher operation directly impact your bottom line:
Tempo de inatividade não programado: Bearing failures or mainshaft issues can halt entire processing plants for days, costing hundreds of thousands in lost production.
Altos custos de manutenção: Freqüente, laborintensive liner changes and component rebuilds consume both budget and critical manpower.
Taxa de transferência inconsistente & Qualidade do Produto: Worn or poorly designed crushing chambers lead to fluctuating product gradation and reduced capacity, bottlenecking downstream processes.
Consumo excessivo de energia: Inefficient crushing action and highfriction components result in unsustainable power draw per ton of material processed.

Is your operation managing these recurring issues, or is it time for a crusher engineered to deliver reliability, eficiência, and longterm cost control?

2. VISÃO GERAL DO PRODUTO

The Premium Gyratory Crusher represents the pinnacle of primary crushing technology for hightonnage, mineração de rochas duras e operações agregadas. Projetado para contínuo, heavyduty service, it is the optimal solution for the initial reduction of runofmine ore or large quarry stone.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Large dump trucks or loaders deposit feed material directly into the crusher’s robust feed hopper.
2. Ação Esmagadora: The hydraulically supported mainshaft assembly gyrates within a concave crushing chamber, applying compressive force to break material against the chamber walls.
3. Descarga do Produto: Crushed material exits through the discharge opening at the bottom of the chamber, with size controlled by the closedside setting (CSS).

Escopo de aplicação & Limitações:
Escopo: Ideal for primary crushing applications with feed sizes up to 1500mm, requiring capacities from 2,000 acabar 10,000 t/h. Suited for abrasive ores (cobre, ouro, ferro) and hard rock aggregates.
Limitações: Not designed for recycled concrete/asphalt or highly plastic/claybound materials. Requires significant capital investment and a stable, fundação de concreto armado.

3. RECURSOS PRINCIPAIS

Côncavo patenteado & Mantle Profile | Base Técnica: Ângulo de nip otimizado e geometria da câmara de britagem | Benefício Operacional: Delivers consistent product gradation with fewer fines generation and reduced risk of bridging | Impacto do ROI: Improved downstream mill throughput by 37% and lower liner wear cost per ton.

Sistema de controle inteligente integrado | Base Técnica: Monitoramento em tempo real do consumo de energia, pressão, and CSS via IoT sensors | Benefício Operacional: Enables predictive maintenance alerts and automatic adjustment for optimal performance | Impacto do ROI: Reduz o tempo de inatividade não planejado em até 30% and optimizes energy consumption.

Spiderless Design & TopService Concept | Base Técnica: Eliminates the traditional spider assembly; all service is performed from above | Benefício Operacional: Dramatically reduces liner changeout time from days to hours with smaller crews | Impacto do ROI: Increases annual crusher availability by over 200 hours while lowering labor costs.

Forged Alloy Steel Mainshaft | Base Técnica: Singlepiece forging from highintegrity alloy steel with enhanced fatigue resistance | Benefício Operacional: Eliminates risk of catastrophic shaft failure under shock loads | Impacto do ROI: Avoids multiweek shutdowns and replacement costs exceeding $500k.

Advanced Lube & Sistema Hidráulico | Base Técnica: Dualcircuit system with automated temperature and contamination control | Benefício Operacional: Ensures positive pressure in bearings yearround, preventing dust ingress and overheating | Impacto do ROI: Prolonga a vida útil do rolamento 40%, significantly cutting maintenance spend.

HeavyDuty Base & Construção de moldura | Base Técnica: Análise de Elementos Finitos (FEA)optimized design using highgrade steel plate | Benefício Operacional: Absorbs dynamic loads without stress fatigue, ensuring decades of structural integrity | Impacto do ROI: Eliminates lifetime costs associated with base repairs or frame cracking.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Premium Gyratory Crusher Solution | Vantagem (% melhoria) |
| : | : | : | : |
| Tempo de troca do revestimento (Conjunto completo) | 72 96 horas | 96%| +24 pontos percentuais |
| Consumo Específico de Energia (kWh/t) Varia de acordo com o material.| Linha de base = 100%| Industry testing demonstrates a reduction to ~93%| ~7% improvement |
| Vida útil do rolamento (L10) Under equivalent conditions.| ~50,000 hours| Field data shows extension to >70,000 horas| +40% melhoria |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 2,500 para 12,000 toneladas métricas por hora.
Requisitos de energia: Classificações do motor de acionamento de 450 kW para mais 1 PM; complete system includes dedicated lube and hydraulic power units.
Especificações de materiais: Concaves/mantles available in premium manganese steel alloys; critical structural components fabricated from ASTM A36/A572 steel; mainshaft forged from SAE 4140/4340 liga.
Dimensões Físicas: Abertura de alimentação até 1.500 mm; total installed height varies by model (aprox.. 6m 9m); total operating weight from 250t 600t+.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 40°C a +50°C; dustsealed construction meets IP66 standards; suitable for highaltitude installations.

6. CENÁRIOS DE APLICAÇÃO

Expansão da mina de cobre em grande escala

Desafio: A planned plant expansion required a primary crusher capable of sustaining >8,000 t/h on highly abrasive porphyry ore while fitting within tight space constraints of an existing pit layout.
Solução: Installation of a single Premium Gyratory Crusher with a compact "spiderless" design profile.
Resultados: Atingiu um rendimento sustentado de 8,400 t/h with product P80 consistently below required spec. Liner life exceeded projections by 15%, contributing to a calculated payback period under three years versus alternative solutions.

HighProduction Granite Quarry

Desafio: Frequent weekend liner changes were creating production bottlenecks. Unpredictable bearing temperatures led to two unscheduled stoppages in one year.
Solução: Implementation of a midrange Premium Gyratory Crusher featuring the TopService Concept and Intelligent Control System.
Resultados:Liner change time reduced from three shifts to one shift (8 horas). The monitoring system provided early warning on lube system health, preventing a potential bearing failure. Annual availability increased to 96.8%.

7. CONSIDERAÇÕES COMERCIAIS

Premium Gyratory Crushers are offered in three primary tiers based on size and duty:
1. Série para serviços pesados: For megamines (>100k tpd), featuring maximum redundancy components. Pricing reflects custom engineering.
2. Série de desempenho: For midtolarge scale mines and major quarries (20k100k tpd). Offers balanced capital/operating cost efficiency.
3. Configured Series: Preengineered models for specific aggregate duties (<15k tpd), offering shorter lead times.

Recursos opcionais & Pacotes:

Advanced Wear Monitoring System (radarbased)
Automated Setting Adjustment Package
Extended Warranty on drivetrain components (up to an additional two years)
Onsite commissioning supervision & operator training programs

Service Agreements: Tailored plans are available covering scheduled inspections, preventive maintenance kits, descontos em peças (up to15%),e tempos de resposta de emergência garantidos.

Opções de financiamento: Flexible commercial structures include capital lease agreements,turnkey project financing,and rentaltoown programs,directly supporting your CAPEX planning cycles.

8.Perguntas frequentes

1º trimestre:What level of site preparation is required comparedto other primary crushers?
UM:The foundation load specifications are comparableto other gyratory crushers of similar capacity.The TopService design often reduces overhead crane requirements,sometimes simplifying support structure design.

2º trimestre:What is the expected operational lifespanof the main structural components?
UM:The base,quadros,and mainshaft housing are engineeredfor a minimumdesign lifeof30years under normal operating conditions when maintained per our guidelines.This is validatedby FEAand historical datafrom earliergeneration units stillin operation after40+years.

Q3.How doesyour intelligent control system integratewith our existing plant DCS/SCADA?
UM:The crusher's control system communicatesvia standard industrial protocols(OPC UA.Modbus TCP/IP).Our engineers will workwith your teamto define the data pointsfor integrationensuring key performance metricsare visibleon your central dashboards without requiring proprietary softwareon your end

Q4.What arethe typical lead timesfor major wear parts like concavesand mantles?
UM:Leveraging global warehousingstrategieswe maintaintarget stock levelsfor critical wear partson our most common models.Aimto ship standard profile linerswithin46weeksfrom order confirmation.Emergency expedite optionsare available

Q5.Do you offerperformance guarantees?
A Yes we provideguaranteesfor rated capacitypower consumptionunder defined feed conditionsand mechanical availabilitysubjectto terms outlinedin our commercial agreement Theseare backedby decadesof field applicationdata