1. ABERTURA ACIONADA POR PAINPOINT

Are you managing the escalating costs and operational headaches of primary crushing in demanding mineral processing or aggregate production? Inefficient gyratory crusher performance directly impacts your entire downstream operation and bottom line. Os principais desafios incluem:

Tempo de inatividade não programado: Bearing failures or mainshaft issues can halt your primary circuit for days, costing hundreds of thousands in lost production.
Altos custos de manutenção: Freqüente, laborintensive liner changes and component wear consume both budget and valuable maintenance crew hours.
Tamanho do produto inconsistente: Poorly controlled discharge settings lead to an inconsistent feed for secondary crushers and mills, reduzindo a eficiência geral da planta.
Ambiental & Supply Chain Compliance Risks: Using components or lubricants that don't meet global environmental standards like RoHS can disrupt your supply chain and limit market access for your products.

How can you achieve higher throughput with greater reliability while ensuring your equipment aligns with modern environmental procurement mandates? The solution requires a crusher engineered from the ground up for durability, precisão, e conformidade.

2. VISÃO GERAL DO PRODUTO

The RoHS Compliant Gyratory Crusher is a primary crushing system designed for highcapacity, continuous size reduction of hard and abrasive ores or rock. It operates via a gyrating mantle within a concave crushing chamber, delivering consistent, hightonnage output for largescale mining and aggregate operations.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Runofmine (ROM) material is directed into the top of the crusher via dump trucks or feeders.
2. Ação Esmagadora: The eccentrically gyrating mantle continuously compresses material against the stationary concaves, achieving size reduction through progressive compression cycles.
3. Descarga: O produto triturado sai pela abertura de descarga na parte inferior, with the size controlled by the vertical position of the mantle.

Escopo de aplicação: Ideal para alta tonelagem (5,000+ TPH) primary crushing stations in metal mines, largescale quarries, and industrial mineral plants processing hard rock like granite, minério de ferro, e minério de cobre.

Limitações: Não adequado para operações de baixa capacidade (< 500 TPH), recycling applications with high tramp metal risk without external protection systems, or processing highly plastic/claybound materials that may cause packing.

3. RECURSOS PRINCIPAIS

Design côncavo patenteado | Base Técnica: Multissegmentado, alloyoptimized geometry | Benefício Operacional: More uniform wear distribution extends service life by up to 30%, reduces changeout frequency | Impacto do ROI: Lower liner cost per ton and less planned downtime for replacements

RoHSCompliant Component & Lubricant System | Base Técnica: Eliminação de substâncias restritas (por exemplo, liderar, mercúrio) in bearings, selos, tintas, e fluidos hidráulicos | Benefício Operacional: Ensures global supply chain compliance, simplifies international shipping and endoflife disposal | Impacto do ROI: Mitigates risk of project delays or fines in regulated markets; futureproofs your asset

Intelligent Chamber Automation | Base Técnica: Hydraulic setting adjustment system with realtime position feedback | Benefício Operacional: Allows operators to adjust CSS remotely for product consistency; automated clearing cycle prevents stall events | Impacto do ROI: Maintains optimal throughput and protects drive train from costly overload damage

Design de concha superior montado em aranha | Base Técnica: Simplified twopiece mainshaft assembly versus traditional threepiece designs | Benefício Operacional: Safer, faster maintenance during mantle or concave changes—reducing service time by an average of 25% | Impacto do ROI: Direct labor savings and increased plant availability

Selo Labirinto & Sistema de Pressão Positiva | Base Técnica: Multistage sealing combined with filtered air blower to create positive pressure at dust seals | Benefício Operacional: Effectively excludes abrasive dust from the eccentric arrangement and lubrication system | Impacto do ROI: Dramatically extends bearing life; reduces oil contamination and associated filtration costs

Acionamento direto & Acoplamento limitador de torque | Base Técnica: Lowspeed synchronous motor coupled via an air clutch or fluid coupling | Benefício Operacional: Provides high starting torque while protecting motor and crusher from shock loads; enables smoother starts under load | Impacto do ROI: Reduces electrical stress on plant infrastructure; lowers risk of catastrophic drive system failure

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Solução de britador giratório compatível com RoHS | Vantagem (% Melhoria) |
| : | : | : | : |
| Vida útil do forro (Minério Abrasivo)| 69 Meses | 912 Meses (with patented design) | +33% Vida útil estendida |
| Mainshaft Bearing MTBF| ~45,000 Hours| >60,000 Horas (with advanced sealing) |>33% Aumento na confiabilidade |
| Concave ChangeOut Time| 4872 Horas| 3648 Horas (with spider design)| 25% Tempo de inatividade de manutenção |
| Consumo de Energia por Tonelada| Linha de base (100%)| ~95% (optimized chamber flow) |5% Specific Energy Use |
| Regulatory Material Compliance| May require verification/waivers| Full RoHS documentation provided| Eliminates Procurement Risk |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 2,000 acabar 12,000 toneladas métricas por hora (MTPH), depending on model size and feed material.
Potência do motor: 300 kW para 800 kW standard models; engineered drives up to 1 MW+ for extraheavy duty applications.
Abertura de alimentação: Ranges from 800mm to 1,500mm dependent on model series.
Principais especificações de materiais: Mainshaft forged from highstrength alloy steel; concaves manufactured from RoHScompliant manganese steel alloys; all paints/coatings free of hexavalent chromium.
Dimensões Físicas (Modelo típico): Total height ~57m; peso instalado entre 150 400 toneladas métricas.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C. Dust sealing effective in environments with particulate concentration up to 10 g/m³.

6. CENÁRIOS DE APLICAÇÃO

Copper Mine Expansion in Chile

Desafio: A major operation needed to increase primary circuit throughput by 20% but faced space constraints and required all new equipment to meet stringent international environmental standards for export markets.
Solução: Installation of a single highcapacity RoHS Compliant Gyratory Crusher replaced two older units.
Resultados: Conseguiu um 22% aumento de rendimento dentro da área ocupada existente. Full RoHS documentation streamlined customs clearance for imported components. Predictive maintenance on the new bearing system prevented an estimated $250k unplanned stoppage in Year 2.

European Granite Quarry Modernization

Desafio: The quarry faced rising maintenance costs on an aging primary crusher and needed compliance with EU directives on hazardous substances in machinery for both operation and future resale value.
Solução: Procurement of a midsize RoHS Compliant Gyratory Crusher as the centerpiece of their plant upgrade.
Resultados: Consistent product gradation improved secondary cone crusher efficiency by 15%. Compliance ensured no marketability restrictions within the EU. Reduced annual liner inventory costs by approximately €40k due to extended wear life.

7. CONSIDERAÇÕES COMERCIAIS

Our commercial model is structured to provide flexibility aligned with capital planning cycles.

Níveis de preços de equipamentos: Offered across three standard series—HeavyDuty (HD), Extra HeavyDuty (XHD), and Super Duty (SD)—with pricing scaling according to capacity ratings and builtin feature sets such as advanced automation packages.
Recursos opcionais: Upgrades include integrated condition monitoring sensors (vibração/temperatura), automated lubrication systems specific to dusty environments, and custom concave profiles for unique material types.
Pacotes de serviços: Choose from Basic Warranty support up to comprehensive Performance Contracts covering scheduled liner changes, annual inspections by factory technicians, and guaranteed parts availability with defined response times.
Opções de financiamento: We work with accredited partners to offer competitive project financing leases operating leases tailored to cash flow requirements enabling you to deploy this critical asset while preserving capital

8. Perguntas frequentes

1. Q What does 'RoHS Compliant' specifically mean for a large crusher?
A It certifies that all homogeneous materials within electrical components mechanical parts subject to EU Directive2011/65/EU such as bearings seals wiring insulation paints contain levels below thresholdsfor restricted substances This ensures no compliance barriersin regulated markets

2 Q Can this crusher integrate with our existing PLC/SCADA control system?
A Yes Standard communication protocols(Modbus TCP/IP OPC UA are supportedfor seamless data exchangeon CSS power draw oil pressureand temperature allowing full integrationinto your central control room

3 Q How does the operational benefitof extended liner life translateinto actual cost savings?
A Field data shows savings are realizedthrough three channels reduced directmaterial cost fewer changeoutsrequiring less laborand increased plant availabilityproducing more revenuegeneratingtonnage overthe same period A detailedROI calculatoris available

4 Q Are there financing optionsavailable beyond standard capitalpurchase?
A Yes We offer several structuredcommercial models includingoperational leases that treatthe equipment as an operatingexpenseand fullservice rental agreementsincluding maintenance whichcan be evaluatedbasedon your financial strategy

5 Q What isthe typical lead timefrom orderto commissioning?
A Lead times varyby modelspecificationand current manufacturingcycle Standard HDseries units typicallyhavea lead timeof months Critical pathitemslike mainshaft forgingsare managedthrough our verticallyintegrated supplychainto ensure reliability