1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão minando a lucratividade do seu circuito de britagem primário? Para gerentes de fábrica e empreiteiros de engenharia, the primary crushing stage is a critical bottleneck where failures have exponential consequences. Common challenges with suboptimal gyratory crushers include:
Tempo de inatividade excessivo não planejado: Mechanical failures or lengthy maintenance procedures can halt upstream mining and downstream processing, custando dezenas de milhares por hora em perda de produção.
Altos custos operacionais: Premature wear part replacement, alto consumo de energia por tonelada processada, and frequent retightening of critical assemblies drive up your costperton metric.
Tamanho do produto inconsistente: Fluctuations in discharge settings lead to poor feed for secondary crushers and milling circuits, reducing overall plant efficiency and recovery rates.
Manutenção Intensiva em Mão de Obra: Complexo, timeconsuming procedures for mantle changes or spider assembly servicing require specialized crews and extend maintenance windows.

Is your operation equipped to handle increasing ore hardness and throughput demands while controlling costs? The foundation of an efficient comminution circuit lies in a reliable, highcapacity primary crusher.

2. VISÃO GERAL DO PRODUTO: HEAVYDUTY GYRATORY CRUSHER

This heavyduty gyratory crusher is engineered for continuous, hightonnage primary crushing of runofmine ore and blasted rock. It operates on the fundamental principle of a gyrating mantle within a concave crushing chamber, delivering consistent compressive breaking force.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Large feed material is directed into the top of the crusher via dump trucks or a shovel, entering the gap between the mantle and concaves.
2. Esmagamento Compressivo: The eccentrically driven main shaft causes the mantle to gyrate, applying progressive compressive force to reduce material size.
3. Descarga: Crushed material falls by gravity through the narrowing chamber until it reaches the desired size and exits through the bottom discharge opening (OSS).
4. Operação Contínua: The design allows for continuous feeding and crushing, making it ideal for highvolume fixedplant applications.

Escopo de aplicação & Limitações:
Escopo: Ideal for largescale mining (cobre, minério de ferro, ouro), major quarry operations, and highcapacity aggregate production requiring throughput from 2,000 acabar 10,000 tph. Excels with hard, materiais abrasivos.
Limitações: Não é adequado para operações de baixa tonelagem (<1000 tph) devido ao alto custo de capital. Requires a stable concrete foundation and significant vertical space for installation. Not designed for recycling or asphalt materials.

3. RECURSOS PRINCIPAIS

Patented QS Spider Design | Base Técnica: Monolithic top shell casting with integrated rim liners | Benefício Operacional: Eliminates traditional spider bushing wear points and reduces risk of dust ingress to the eccentric bushing | Impacto do ROI: Os dados de campo mostram um 40% reduction in spiderrelated maintenance time and associated costs.

Selo Labirinto & Piston Ring System | Base Técnica: Multistage sealing protecting critical eccentric components | Benefício Operacional: Prevents contamination from dust and water ingress while allowing lubrication system to function optimally | Impacto do ROI: Extends major bearing service life by up to 30%, deferring sixfigure rebuild costs.

Regulamento de configuração automatizada (RAS) | Base Técnica: Hydromechanical adjustment system with digital control interface | Benefício Operacional: Allows operators to adjust crusher discharge setting under load in minutes versus hours | Impacto do ROI: Minimiza o tempo sem esmagamento; testes da indústria demonstram uma 15% increase in annual available operating hours.

Côncavo & Mantle Alloy Optimization | Base Técnica: Metallurgical analysis leading to proprietary manganese steel alloys with microalloying elements | Benefício Operacional: Provides optimal balance of hardness and toughness for specific ore abrasiveness/impact | Impacto do ROI: Entrega até 20% longer service life per set compared to standard OEM parts, reduzindo o custo por tonelada.

Integrated Smart Sensor Platform | Base Técnica: Realtime monitoring of pressure, temperatura, posição, and vibration at key bearing points | Benefício Operacional: Enables predictive maintenance scheduling by identifying trends before failure occurs | Impacto do ROI: Reduces unplanned stoppages by an estimated 60%, protecting downstream revenue flow.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nossa solução de britador giratório | Vantagem documentada |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | 92 94% disponibilidade anual >95% disponibilidade anual >3% melhoria |
| Consumo de energia (kWh/tonelada) Varia de acordo com o material; linha de base = 100% Até 12% reduction in specific energy Improved motor load efficiency |
| Mantle Change Out Time Average 2436 hours Average <20 hours ~30% faster turnaround |
| Vida útil da peça (Convexes) Linha de base = 100% lifecycle Up to +20% extended life Lower consumable cost per ton crushed |
| Throughput Capacity Rated design capacity Consistently achieves +57% above rated capacity Higher peak tonnage capability |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Modelos configuráveis ​​de 2,000 TPH acima 12,000 TPH based on feed size and material characteristics.
Potência do motor: Heavyduty synchronous motors from 450 kW até 1,200 kW (600 1,600 HP), tailored to duty requirements.
Abertura de alimentação: Tamanhos de abertura de 1,370 milímetros (54") até 1,830 milímetros (72").
Quadro Principal & Componentes: Fabricado em chapa de aço de alta resistência; mainshaft forged from highstrength alloy steel; concaves/mantles in premiumgrade manganese steel alloys.
Dimensões Físicas (Modelo grande típico): Total height ~67 meters; installed weight approximately 350 550 toneladas métricas (excluindo funil de alimentação).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 40°C a +50°C; dustproofed enclosures standard; pacotes opcionais para o Ártico ou tropical disponíveis.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Mina de Cobre

Desafio: Uma grande operação de cobre necessária para aumentar o rendimento da planta em 25% but was constrained by an aging primary crusher causing weekly unplanned downtime events.
Solução: Installation of a new highcapacity gyratory crusher with integrated smart sensors and automated setting controls.
Resultados: Achieved sustained throughput at +28% above old capacity with annual availability reaching 96%. Predictive alerts reduced mechanical downtime by over USD $1.2M in lost production value in the first year.

Pedreira de agregado de granito

Desafio: High silica content granite was causing accelerated concave wear every six weeks on existing equipment, leading to frequent costly shutdowns and inconsistent product gradation.
Solução: Implementation of a robust gyratory crusher paired with applicationspecific concave alloy liners.
Resultados:Liner service life extended to nine weeks consistently while maintaining tighter product size control (+/5milímetros). This change yielded a direct reduction in liner inventory costs by onethird annually.

7. CONSIDERAÇÕES COMERCIAIS

Our wholesale distribution model provides direct access without intermediary markups.

Níveis de preços: Pricing is structured based on size/capacity (por exemplo, MKII series vs MKIII series), starting at entrylevel capital investment scaling appropriately for larger configurations.
Recursos opcionais & Pacotes: Key options include advanced lubrication filtration systems fully automated wear part monitoring packages custom feed plate designs for sticky material conditions extended warranty plans covering major structural components
Pacotes de serviços: Choose from Bronze Silver Gold tiers covering scheduled inspections parts supply predictive analytics support emergency field service response times
Opções de financiamento: We facilitate partnerships with industrial equipment financiers offering competitive leasetoown structures operating expensebased financing or traditional term loans tailored project financing can be arranged

8. Perguntas frequentes

Q1 Are your gyratory crushers compatible with existing plant infrastructure like feeders conveyors bins?
A1 Yes dimensional drawings power requirements foundation loads are provided early Standard discharge hoppers can be adapted Interface points are designed according global standards ensuring integration feasibility

Q2 What is typical installation commissioning timeline?
A2 For greenfield projects total timeline depends on foundation readiness Typically erection takes weeks followed by days mechanical commissioning weeks supervised performance testing Brownfield replacements can be expedited

Q3 How does this equipment impact my overall plant energy consumption?
A3 The optimized kinematics higher efficiency motors result lower specific energy use kWh per ton crushed This reduces operational expenditure improves sustainability metrics

Q4 What commercial terms are standard?
A4 Standard terms involve progress payments tied manufacturing milestones FOB shipping point Incoterms Longterm partners may qualify net payment terms after established credit history

Q5 What training is provided operational staff?
A5 Comprehensive training covers safe operation routine maintenance troubleshooting procedures Training conducted onsite during commissioning includes detailed manuals digital resources

Q6 Can you supply wear parts compatible other OEM crushers?
A6 Yes our foundry produces premium compatible liners spiders other wear components several legacy models often superior metallurgy competitive pricing

Q7 How do you handle urgent breakdown situations?
A7 Our Goldtier service package guarantees priority parts dispatch dedicated technical support hotline If required field service engineers can be mobilized within agreed response windows detailed SLA