1. ABERTURA ACIONADA POR PAINPOINT

Managing a limestone quarry or processing plant presents distinct, desafios dispendiosos. Are you experiencing persistent bottlenecks that limit your operation’s true capacity? Os pontos problemáticos comuns incluem:
Excessive Primary Crusher Downtime: Bridging and clogging at the primary crushing stage due to oversized, slabby feed material halts entire production lines, custando milhares por hora em perda de rendimento.
Unpredictable Feed Size to Downstream Processes: Inconsistent fragmentation from the muck pile leads to poor crusher performance, increased wear on conveyor systems, and inefficient sizing for kiln feed or aggregate products.
High Operational Costs from Secondary Breakage: Reliance on hydraulic hammers for secondary breaking is laborintensive, lento, and incurs substantial costs in tool wear, fuel, and equipment maintenance.
Safety and Vibration Concerns: Secondary breaking and inefficient primary blasting can generate excessive ground vibration, posing regulatory compliance risks and community relation issues near sensitive boundaries.

A questão central é: how can you achieve a consistently fragmented, optimally sized feed from the face to your primary crusher to maximize plant uptime and reduce downstream processing costs?

2. VISÃO GERAL DO PRODUTO

The solution is a highcapacity Primary Gyratory Crusher engineered specifically for hightonnage limestone mining operations. This equipment serves as the cornerstone of your raw material handling system, designed to accept runofquarry limestone directly from the haul trucks.

Fluxo de Trabalho Operacional:
1. Direct dump of shot limestone from haul trucks (up to 2meter top size) into the crusher’s large feed hopper.
2. The gyrating mantle within the fixed concave crushes material via compressive force, reducing it by a factor of 6:1 para 8:1.
3. Crushed product discharges onto the main plant conveyor at a consistent size (tipicamente <250milímetros), ready for secondary crushing or screening.

Escopo de aplicação: Ideal para operações em pedreiras de grande escala com produção anual superior 1 milhões de toneladas. It is designed for continuous, 24/7 operation under heavy load.

Limitações: Not suitable for smallscale quarries or portable crushing setups due to significant foundation requirements and capital investment. Requires consistent, planned maintenance shutdowns.

3. RECURSOS PRINCIPAIS

Patented NonChoking Concave Profile | Base Técnica: Steepsided feed opening with optimized curvature | Benefício Operacional: Eliminates bridging of slabby limestone; ensures continuous material flow even with high clay content | Impacto do ROI: Reduces crusher stall events by up to 90%, directly increasing available crushing hours

Regulação de configuração automática integrada (RAS) Sistema | Base Técnica: Hydropneumatic adjustment with realtime position sensors | Benefício Operacional: Maintains target discharge setting without manual intervention; compensates for mantle wear automatically | Impacto do ROI: Delivers consistent product sizing (+/ 5% tolerance), improving downstream efficiency and reducing product waste

HeavyDuty Main Shaft & Spider Assembly | Base Técnica: Forged alloy steel shaft with premium bronze bushing design | Benefício Operacional: Withstands extreme shock loads from uncrushable material; provides reliable service life exceeding 10 years in abrasive limestone | Impacto do ROI: Lowers lifetime cost of ownership via extended major component life and reduced risk of catastrophic failure

Lube System with Dual Coolers & Filtration | Base Técnica: Redundant cooling circuits and offline filtration unit | Benefício Operacional: Maintains optimal bearing temperature in highambient conditions; continuously purges contaminants from oil | Impacto do ROI: Extends bearing service intervals by up to 50%, decreasing lubrication costs and unplanned downtime

Smart Chamber Design & Monitoramento de desgaste | Base Técnica: Modular concave segments with embedded wear sensors | Benefício Operacional: Allows for strategic rotation/replacement of wear parts; provides predictive maintenance data on remaining liner life | Impacto do ROI: Optimizes liner changeout schedules during planned stops, maximizing utilization and parts investment

Lubrificação Centralizada & PLC Control Hub | Base Técnica: Automated singlepoint greasing for all bearings integrated into plant control system | Benefício Operacional: Simplifies routine maintenance; provides operators with realtime performance dashboards and fault diagnostics | Impacto do ROI: Reduces daily lubrication labor by 75% and shortens troubleshooting time significantly

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Cone/Jaw Crusher Plants) | Solução de britador giratório primário | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade)| 8590% due to bridging & more frequent liner changes| 9496% through nonchoking design & maior vida útil| +7% disponibilidade operacional |
| Tonnage per Installed HP| Lower ratio due to intermittent feeding & projeto de câmara| Higher ratio via continuous crushing action & optimal kinematics| +1520% eficiência energética |
| Feed Top Size Capability| Limited by gape dimension; often requires prescreening| Accepts larger direct dump feed (up to 2m), simplifying loadout| Eliminates prescreening stage |
| Custo por tonelada (Peças de desgaste)| Higher cost due to faster wear rates in abrasive limestone| Lower cost via massive liner design & strategic wear monitoring| 25% cost per ton crushed |
| Manpower for Operation| Often requires dedicated crusher operator/feeder watcher| Fully automated operation integrated with PLC/SCADA system| 1 FTE requirement |

5. ESPECIFICAÇÕES TÉCNICAS

Designação do modelo: GY5460 HD Limestone
Faixa de capacidade: 2,500 – 4,500 toneladas por hora (dependent on CSS and material work index)
Abertura de alimentação: 1,370 milímetros
Tamanho máximo de alimentação: 2,000 milímetros (slabby limestone)
Nominal Discharge Setting Range: 150 – 250 milímetros
Potência Instalada: 450 kW (600 HP) electric drive
Peso total (Apenas triturador): ~275 tonnes
Principais especificações de materiais: Manto & Concaves – Manganese steel alloy with patented workhardening matrix; Main Shaft – Forged 34CrNiMo6; Base Frame – Fabricated heavyduty steel.
Dimensões Físicas (LxWxH): ~6.5m x ~5m x ~4.5m (above foundation).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C. Dust sealing rated for IP66.

6. CENÁRIOS DE APLICAÇÃO

Large Cement Plant Quarry Integration

Desafio: A major cement producer faced inconsistent kiln feed quality due to fluctuating limestone size from their old jaw crusher circuit, causing inefficiencies in raw mill operation and higher specific energy consumption.
Solução: Installation of a GY5460 HD Primary Gyratory Crusher as the new first reduction stage.
Resultados: Achieved a consistent 200mm crusher product. This stabilized raw mill feed, resulting in a documented 8% reduction in specific energy consumption at the mill and a 12% increase in overall plant throughput due to eliminated upstream bottlenecks.

HighVolume Aggregate Quarry Expansion

Desafio: An aggregate producer needed to expand annual output but was constrained by primary crushing capacity. Their existing system required frequent secondary breaking and suffered from daily bridging incidents.
Solução: Commissioning of two parallel GY5460 HD crushers fed directly by 90ton haul trucks.
Resultados：Bridging incidents were eliminated. The quarry increased average hourly throughput by over 40%, meeting expansion targets without adding a third shift. Secondary hammer operating costs were reduced by over 60%.

7. CONSIDERAÇÕES COMERCIAIS

Equipment pricing is structured around configuration tiers:
Camada de configuração básica: Inclui triturador, drive motor, lubrication system, and basic PLC controls.
Advanced Optimization Tier: Adds ASR System, integrated wear monitoring sensors, advanced predictive maintenance software suite.
Turnkey Installation Tier: Full engineering package including foundation design drawings, installation supervision,and commissioning services.

Optional features include dust suppression ring kits,tramp metal detection systems,and custom discharge conveyor flanges.

Service packages are offered as annual Performance Care Agreements covering planned inspections,predictive analytics review,and priority parts supply.Financing options include capital purchase,direct leasetoown models,and throughputbased agreements tailoredfor largescale projects.

8. Perguntas frequentes

1º trimestre：Is this primary gyratory crusher compatible with our existing downstream secondary cone crushersand screening plant?
A1：Yes.Field data shows its abilityto producea consistent,fineslimited product optimizes loadingand performanceof downstream stages.Engineering supportis providedto ensure interface compatibilitywith your existing conveyorsand chutework.

2º trimestre：What isthe typical implementation timelinefrom orderto commissioning?
A2：Fora standard model,the lead timeis approximately89 months.Foundation constructioncan proceedin parallel upon receiptof detailed drawings.Onsite erectionand mechanical commissioningtypically require810 weekswith our supervision.

3º trimestre：How doesthe automated setting regulationimpact final product specificationfor our aggregate products?
A3：The ASR systemmaintainsa tighter discharge setting tolerance.This directly translatesintoa more consistentfeedfor your secondary/tertiary stages,yielding superior controlover final aggregate gradationand increased yieldof inspecproduct.

4º trimestre：What arethe critical spare partswe should planto stock?
A4：We recommendan initial spare parts kitincluding concave segments,manto,bushing kits,and hydraulic cartridge filters.Ourbasedon your specific production forecastand local logisticsupport times.

Q5：Can this equipment handlethe occasional siliceous bandor chert nodulefoundin our limestone deposit?
A5：Yes.The heavyduty designincorporatesa hydroset systemthat allows the c rus herto pass uncrushablematerialby temporarily openingthe discharge setting,thereby providingprotection against tramp materialdamage.The robust main shaftassemblyis engineeredfor such shock loads.

Q6：What trainingis providedfor our maintenance crew?
A6：Comprehensive trainingis includedcovering operational procedures,scheduled maintenance tasks,troubleshooting usingthe PLC interface,and safety lockout protocols.This consistsof both classroominstructionand handson sessionsduring commissioning.

Q7：Are there financing options that align paymentwith achievingprojected production volumes?
A7：Yes.We offer structured financing solutionswhere repayment schedulescan be linkedto operational milestonesor throughput volumes.This helps manageinitial capital outlayand aligns ourobjectiveswith your production success