1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e a disponibilidade imprevisível estão minando a lucratividade do seu circuito de britagem primário? Para gerentes de fábrica e empreiteiros de engenharia, the primary gyratory crusher is a critical asset where failures have exponential consequences. Os desafios comuns incluem:
Tempo de inatividade não programado: Bearing failures or mantle wear issues can halt upstream mining and downstream processing for days, custando dezenas de milhares por hora em perda de produção.
Mão de obra de alta manutenção & Custos de peças: Freqüente, complex liner changes and manual adjustments consume hundreds of manhours annually and drive up spare parts inventory costs.
Tamanho do produto inconsistente: Britadores desgastados ou mal ajustados produzem alimentação fora de especificação para circuitos secundários, reducing overall plant throughput and recovery rates.
Ineficiência Energética: Older or poorly optimized designs draw excessive power per ton of material processed, impactando diretamente as despesas operacionais.

Is your operation constrained by these recurring issues? A solução não está em atualizações incrementais, but in a fundamentally reengineered approach to primary crushing.

2. VISÃO GERAL DO PRODUTO

The Private Label Gyratory Crusher is a heavyduty, primary compression crusher engineered for the first stage of reducing runofmine ore to a manageable size for conveying and further processing. Its operational workflow is based on a reliable gyrating mantle within a concave crushing chamber:

1. Ingestão de ração: Large runofmine material is directed into the top of the crusher’s deep chamber via dump trucks or feeders.
2. Esmagamento Compressivo: The eccentrically gyrating mantle continuously compresses material against the stationary concaves, applying progressive rockonrock and rockoniron reduction.
3. Controle de configuração de descarga: The crushed product exits at the bottom opening; its size is precisely controlled by adjusting the vertical position of the mantle via the hydroset system.

Escopo de aplicação: Ideal para alta tonelagem (5,000+ TPH) mining operations processing hard rock ores (ferro, cobre, ouro) e agregados. It is the preferred choice for slabby feed material and sticky clays that would challenge jaw crushers.

Limitações: Não é adequado para operações de baixa tonelagem (<1,000 TPH) devido ao alto custo de capital. Requires significant foundational support and a controlled feed system to operate at peak efficiency.

3. RECURSOS PRINCIPAIS

Patented ASRi+ Automation System | Base Técnica: Monitoramento de condição em tempo real & adaptive crushing logic | Benefício Operacional: Mantém automaticamente a carga ideal do britador e a configuração do lado fechado (CSS) for varying feed conditions | Impacto do ROI: Os dados de campo mostram consistência 510% throughput increase and up to 15% reduction in liner wear costs

Segmented Concave & Mantle Design | Base Técnica: Modular wear part segments with advanced alloy chemistry | Benefício Operacional: Enables partial liner replacement during scheduled maintenance, drastically reducing changeout time from days to hours | Impacto do ROI: Reduz o tempo de inatividade para troca de revestimento em até 60%, lowering labor costs and production loss

Integrated Lube & Sistema Hidráulico | Base Técnica: Redundant filtration circuits with temperature control | Benefício Operacional: Ensures continuous clean oil flow to critical bearings and the hydraulic setting adjustment (Hidroset), preventing thermal shutdowns | Impacto do ROI: Os testes da indústria demonstram uma >40% reduction in bearingrelated failures over a 5year period

Spiderless Top Shell Design | Base Técnica: Eliminates traditional spider arms through reinforced rim design | Benefício Operacional: Removes potential bottlenecks for large feed material; simplifies access for maintenance | Impacto do ROI: Increases effective feed opening utilization by ~20%, reducing bridging risk

BottomShell Eccentric Bushing Design | Base Técnica: Grande diâmetro, precisionmachined bushing with forced lubrication | Benefício Operacional: Provides exceptional stability under shock loads from uncrushable material; extends major component life | Impacto do ROI: Projects show major overhaul intervals extended by 23 years compared to legacy designs

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Linha de base padrão da indústria | Private Label Gyratory Crusher Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Tempo de atividade operacional) | 92 94% | 96 98% sustained availability target| +4% melhoria |
| Consumo Específico de Energia (kWh/t) Varies by material hardness| Linha de base = 100%| Geometria otimizada da câmara & drive efficiency reduces consumption| Até 7% redução |
| Tempo de troca do revestimento (Principal)| ~72 hours| Segmented design & tooling reduces time to 58% mais rápido |
| Tempo médio entre falhas (MTBF) Componentes Principais| ~24 months typical for bearings/bushings under heavy load| Enhanced lubrication & metallurgy increases MTBF target| Alvo de +50% melhoria |
| Consistência de rendimento (Tonnage Variance)| +/ 10% with manual CSS adjustment| ASRi+ automation maintains CSS within +/ 3variação mm|< +/ 5% variação |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Modelos configuráveis ​​de 2,000 acabar 15,000 toneladas métricas por hora (tph).
Potência do motor: Dependente do tamanho do modelo; faixa padrão de 450 kW para mais 1,200 kW. Designed for direct online starting with softstart options.
Abertura de alimentação: Tamanhos de abertura de 1,000 mm para 1,600 milímetros.
Especificações de materiais:
Quadro Principal & Concha superior: Highstrength fabricated steel (ASTM A36 equivalent or higher).
Côncavo & Mantle Core: Ligas de aço manganês (1114% Mn), with optional premium alloys for highly abrasive ores.
Excêntrico & Bushings: Forged steel with Babbitt metal lining.
Dimensões Físicas & Peso: Varia significativamente por modelo; largest models exceed 12m in height with installed weights over 500 toneladas. Foundation loading data provided per project.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 30°C a +50°C. Dust sealing systems are rated for IP65 protection.

6. CENÁRIOS DE APLICAÇÃO

Expansão da Mina de Cobre, Ámérica do Sul

Desafio: An expanding openpit operation needed to increase primary crushing capacity by 25%. Their existing crushers suffered from frequent downtime due to thermal events in the lube system and slow mantle changes causing production bottlenecks.
Solução: Installation of one new Private Label Gyratory Crusher featuring the integrated lube system with cooling redundancy and segmented mantle design.
Resultados: Atingiu um rendimento sustentado de 8,500 tph. Tempo de troca do revestimento reduzido de 68 para 26 horas. Disponibilidade anual registrada em 97.3%, exceeding plant targets.

Operação de pedreira de granito em grande escala

Desafio: Highly variable feed size from blasting led to constant operator intervention on CSS adjustment, causing inconsistent product gradation for secondary cone crushers and increased recirculating load.
Solução: Retrofit of an existing gyratory crusher station with the Private Label ASRi+ Automation System package.
Resultados: Product size distribution variability improved by over 60%. A produtividade aumentou em média 8% without increasing power draw. Operators were redeployed to other supervisory tasks.

7. CONSIDERAÇÕES COMERCIAIS

Níveis de preços: Oferecido em três níveis de engenharia de valor:
Dever Padrão: Para consistente, less abrasive feeds (por exemplo, calcário). Most costeffective CAPEX.
Serviço Pesado: Standard specification for most hard rock mining applications; includes core features like segmented liners.
Dever Extremo: For highly abrasive ores or severe operating conditions; includes premium metallurgy packages and enhanced monitoring systems as standard.

Recursos opcionais / Pacotes: ASRi+ Automation System upgrade kit; Pacote de vedação para supressão de poeira; Advanced Predictive Monitoring Sensors; Customized Tooling Kits for maintenance.

Pacotes de serviços: Multitiered annual service agreements are available covering planned maintenance inspections, envio prioritário de peças (+24/7 critical coverage), suporte para diagnóstico remoto, and lifecycle optimization reporting.

Opções de financiamento: Flexible capital equipment financing can be structured through partners including operating leases tailored to project cash flow models or traditional term loans.

8. Perguntas frequentes

1º trimestre: Is this gyratory crusher compatible with my existing plant control system?
A1 Sim. The control interface is designed using open communication protocols (Modbus TCP/IP). It can be integrated as a standalone unit or fully into your central SCADA/DCS system.

Q2 What is the expected impact on my operational staffing?
A2 The automation features reduce the need for constant manual adjustment but do not eliminate skilled operator oversight. Your team will transition towards monitoring performance analytics and planning predictive maintenance rather than reactive adjustments.

Q3 How does your total cost of ownership compare over ten years?
A3 While initial capital investment may be comparable or slightly higher than some alternatives our field data indicates significantly lower operating costs leading typically yielding a lower total cost ownership after years twothree Key savings areas are energy consumption liner wear parts labor

Q4 Quais são os prazos de entrega do suporte à instalação?
A4 Lead times vary model complexity Current standard lead time manufacture shipping ranges months months Projectspecific schedules are provided upon application review We provide comprehensive installation supervision commissioning services ensure correct setup performance validation

Q5 Can you provide wear part guarantees based specific ore characteristics?
A5 Yes We offer conditional performance guarantees our liners based detailed analysis your ore sample Our metallurgists will specify alloy recommend profile maximize service life tonnage crushed specific application