1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo as margens do seu projeto? Para gerentes de fábrica e empreiteiros de engenharia, primary crushing is a critical bottleneck where failures cascade into costly delays. Os desafios comuns incluem:
Desgaste Excessivo & Spare Parts Costs: Premature failure of jaw dies and components due to poor material selection or design, levando a frequentes, expensive changeouts and parts inventory burdens.
Tempo de inatividade não programado: Unplanned stoppages from mechanical failures or blockages disrupt the entire downstream process, custando milhares por hora em perda de produção.
Taxa de transferência inconsistente & Formato do produto: Fluctuations in feed material cause capacity drops and poor product gradation, impacting secondary crusher efficiency and final product specification.
Alto consumo de energia: Inefficient crushing chambers and drive systems result in disproportionate power draw per ton of material processed.
Rigidez & Questões de Fundação: Equipment vibration and dynamic forces necessitate overengineered, costly foundations and can lead to longterm structural fatigue.

Como você seleciona um britador primário que oferece desempenho previsível, minimiza o custo total de propriedade, and provides the structural integrity for decades of service? The solution requires engineering focused on durability, eficiência, e simplicidade operacional.

2. VISÃO GERAL DO PRODUTO

O Premium JC5000 é um serviço pesado, Britador de mandíbulas simples projetado para britagem primária de alta capacidade em mineração exigente, pedreira, e aplicações de construção em grande escala. Its design prioritizes mechanical robustness and sustained throughput in continuous operation.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Grande material de mina ou pedreira (até 1300 mm) é direcionado para as profundezas, câmara de britagem sem asfixia.
2. Ação Esmagadora: Um volante de alta inércia aciona um movimento elíptico agressivo na mandíbula móvel, aplicando força compressiva intensa para reduzir o material.
3. Descarga & Liberação: The optimized discharge setting allows crushed material to exit freely without restriction, while the hydraulic toggle system provides instant unblocking capability.
4. Transporte de Produto: Sized product is discharged onto the primary conveyor for transport to the next stage of processing.

Escopo de aplicação: Ideal para hard rock (granito, basalto), minério de ferro, e agregados abrasivos. Suitable for stationary plants and large mobile tracked setups.
Limitações: Not designed for recycling applications with high levels of rebar or tramp metal without appropriate prescreening protection. Requires a planned maintenance regimen consistent with all capital equipment.

3. RECURSOS PRINCIPAIS

Conjunto de rolamento de rolo para serviços pesados | Base Técnica: Spherical selfaligning roller bearings on both eccentric shaft and swing jaw | Benefício Operacional: Handles high radial and thrust loads with minimal friction; supports sustained high horsepower input | Impacto do ROI: Proven bearing life exceeding 24,000 hours reduces replacement frequency by an estimated 40% versus standard bearings.

Alternar Hidráulico & Sistema de ajuste | Base Técnica: Integrated hydraulic cylinder replaces conventional mechanical toggle plates | Benefício Operacional: Enables remote adjustment of crusher setting for product size changes and provides safe, rapid clearing of stalled chambers | Impacto do ROI: Reduces downtime for clearing blockages from hours to minutes; eliminates manual shim adjustments.

Eixo excêntrico forjado & Robust Frame | Base Técnica: Highstrength alloy steel shaft; stressrelieved fabricated steel frame with reinforced ribs | Benefício Operacional: Withstands peak shock loads from uncrushable material; maintains alignment under maximum load conditions | Impacto do ROI: Elimina o risco de falha catastrófica do eixo; foundation costs can be reduced by up to 15% due to superior dynamic stability.

Geometria otimizada da câmara de britagem | Base Técnica: Computermodeled kinematics ensure steep nip angle and deep vertical chamber profile | Benefício Operacional: Promotes aggressive bite and efficient reduction throughout the cycle; minimizes bridging and enhances throughput per stroke | Impacto do ROI: Os dados de campo mostram uma consistência 812% increase in tons per hour compared to previousgeneration designs with equivalent power.

EasyMaintenance Design Philosophy | Base Técnica: Symmetrical frame design allows reversible mounting of jaw dies; accessible grease lines and centralized lube points | Benefício Operacional: Extends wear part life by utilizing both ends of jaw dies; simplifies routine servicing tasks for technicians | Impacto do ROI: Reduces liner inventory requirements; cuts planned maintenance time by an estimated 30%.

Volantes de alta inércia | Base Técnica: Precisely balanced heavyduty flywheels store kinetic energy during each cycle | Benefício Operacional: Smoothes out power demand peaks, ensuring consistent crushing force even under variable feed conditions | Impacto do ROI: Protege os componentes da unidade contra cargas de choque; contributes to lower overall specific energy consumption (kWh/tonelada).

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Classe comparável) | Solução Premium JC5000 | Vantagem (% melhoria) |
|||||
| Mandíbula morre vida (Rocha Abrasiva)| ~450.000 MT | Até 600,000 MT | +33% |
| Disponibilidade (Tempo de atividade %) | 9092% | Consistentemente acima 95% | +35% |
| Consumo Específico de Energia | ~0,85 kWh/ton | Tão baixo quanto 0.78 kWh/tonelada | 8% |
| Throughput @ CSS 200mm | ~750 MT/h | ~850 MT/h | +13% |
| Major Bearing Service Life | ~18,000 hours | >24,000 horas | +33% |

5. ESPECIFICAÇÕES TÉCNICAS

Abertura de alimentação: 1300mm x 1000 mm (51" x 40")
Tamanho máximo de alimentação: Up to 1100mm (43")
Faixa de configuração do lado fechado: 150 300milímetros (6" 12")
Faixa de capacidade (Varia de acordo com o material & CSS): Até 1100 MTPH
Requisitos de energia da unidade: 200 kW / Opções de até kW disponíveis
Peso total (Apenas triturador): Approximately kg
Principais especificações de materiais: Forged EN24/S155Cr3 Eccentric Shaft; HighStrength Fabricated Steel Main Frame; Manganese Steel Jaw Dies (14%,18%,22% disponível).
Faixa de temperatura operacional: 20°C a +45°C (4°F a +113°F) com lubrificantes apropriados.

6. CENÁRIOS DE APLICAÇÃO

Hard Rock Quarry Expansion – Australia

Desafio: A granite quarry needed to increase primary circuit throughput by over % but was constrained by existing foundation limits and high wear costs on their legacy crusher.
Solution Installation of a Premium JC5000 jaw crusher with its optimized dynamic footprint replaced two older units.
Resultados alcançados % increase in base layer production while reducing specific liner cost per ton by %. The stable operation allowed use of the existing feed structure with minimal reinforcement.

Iron Ore Primary Crushing – West Africa

Challenge Severe abrasion causing swing jaw bearing failures every months at a remote site logistics nightmare), coupled with excessive energy costs.
Solution Deployment of the JC5000 with its heavyduty roller bearing assembly optimized chamber geometry
Results Bearing service life extended beyond months eliminating two major changeouts per year Plant energy monitoring showed a % reduction in specific power consumption translating directly lower diesel generator fuel costs

7 CONSIDERAÇÕES COMERCIAIS

The Premium JC5000 is offered as capital equipment within established global pricing tiers based on final configuration

Base Configuration Includes crusher motor motor mounts flywheel guards basic tool kit Optional Features Hydraulic setting adjustment package automated grease lubrication system wear monitoring sensors various manganese steel grades special protective coatings

Service Packages Tiered offerings from basic commissioning supervision comprehensive multiyear planned maintenance agreements including parts kits financing Options Available through partnered financial institutions covering leasetoown operating leases traditional purchase structures tailored project finance

8 Perguntas frequentes

Quais são os requisitos básicos para o JC5000?
Detailed dynamic load drawings are provided Our design distributes forces effectively but a sitespecific civil engineering review is mandatory We supply all necessary interface data

Can this crusher handle very wet sticky material?
While capable modifications like steeper nip angles specific liner profiles can be specified However highly claybound material may require prescreening scalping for optimal performance

What is the expected delivery lead time?
Standard configurations typically have lead time between weeks subject current order book confirmation Customized builds require additional engineering time

Do you provide wear parts after purchase?
Yes we maintain full OEM spare parts support including genuine manganese dies bearings other critical components ensuring original performance specifications are maintained

Is operator training included?
Comprehensive onsite training covering operation daily checks routine maintenance troubleshooting is included standard commissioning package

What warranty applies?
The Premium JC5000 carries standard months warranty on materials workmanship extended warranties available purchase specific components