Rohs Compliant Gyratory Crusher Brochure
1. PAINPOINT DRIVEN OPENING
Are you facing escalating operational costs and unpredictable availability in your primary crushing circuit? Common challenges with traditional gyratory crushers include excessive liner wear leading to frequent maintenance shutdowns, high energy consumption per ton of processed material, and inconsistent product gradation that stresses downstream processes. These issues directly impact your bottom line through unplanned downtime, rising spare parts inventories, and suboptimal plant throughput.
How can you achieve more tons between maintenance intervals? Is it possible to reduce your energy cost per ton while maintaining precise discharge settings? What would a 20% improvement in crusher availability mean for your annual production targets? The solution requires a fundamental reengineering of the gyratory crusher’s core components and lubrication philosophy.
2. PRODUCT OVERVIEW
The Rohs Compliant Gyratory Crusher is a primary crushing machine engineered for highcapacity, continuous operation in demanding mining and aggregate applications. It is designed to accept large feed material from haul trucks or loaders and reduce it to a consistent, conveyable size for secondary processing.
Operational Workflow:
1. Feed: Large runofmine (ROM) rock is directed into the crushing chamber via a feed hopper.
2. Crushing Action: A vertically oriented mantle gyrates within a concave bowl, applying compressive force to the rock against the stationary concaves.
3. Discharge: Crushed material gravitates through the narrowing gap at the chamber's bottom, exiting through the discharge opening set by the mainshaft position.
Application Scope: Ideal for hightonnage primary crushing stations in hard rock mining (copper, iron ore, gold), largescale aggregate quarries, and industrial mineral operations.
Limitations: Not suitable for highly abrasive recycling materials without specific liner configurations or for operations requiring extreme portability.
3. CORE FEATURES
Patented Liner Profile | Technical Basis: Optimized crushing chamber geometry based on DEM (Discrete Element Modeling) | Operational Benefit: Promotes interparticle crushing, reduces wasteful sliding wear on liners, and produces a more cubical product | ROI Impact: Field data shows up to 30% longer liner life, reducing cost per ton for wear parts.
HighEfficiency Drive System | Technical Basis: Direct gearless drive with variable frequency control (VFC) | Operational Benefit: Eliminates traditional pinionandgear losses, provides smooth startup under full load, and allows realtime adjustment of crusher stroke | ROI Impact: Industry testing demonstrates 1218% lower energy consumption compared to standard geared drives.
Integrated Smart Lubrication | Technical Basis: Conditionbased oil filtration and cooling with realtime particle monitoring | Operational Benefit: Maintains optimal oil cleanliness and temperature, preventing premature bearing failure and viscosity breakdown | ROI Impact: Extends major lubrication service intervals by 2x, reducing fluid costs and downtime risk.
Automated Setting Adjustment System (ASAS) | Technical Basis: Hydraulic mainshaft positioning with digital feedback sensors | Operational Benefit: Allows remote or automated adjustment of the closedside setting (CSS) for consistent product size without stopping the crusher | ROI Impact: Improves overall plant consistency; eliminates manual adjustment downtime.
Robust Spider Design | Technical Basis: Forged alloy steel construction with optimized ribbing for stress distribution | Operational Benefit: Provides maximum stability for the top bearing assembly under shock loads from uncrushable material | ROI Impact: Minimizes risk of catastrophic structural damage, protecting your longterm asset value.
EcoGard Sealing System | Technical Basis: Multistage labyrinth seals with positivepressure air purge | Operational Benefit: Effectively excludes dust from the eccentric bushing and drive system while retaining lubricant | ROI Impact: Dramatically increases component life in dusty environments; reduces seal replacement frequency.
4. COMPETITIVE ADVANTAGES
| Performance Metric | Industry Standard | Rohs Compliant Gyratory Solution | Advantage (% improvement) |
|||||
| Liner Life (Abrasive Ore) | 450,000 550,000 tons | 650,000 700,000 tons | +20% |
| Energy Consumption | 0.85 1.0 kWh/t | 0.72 0.80 kWh/t | 15% |
| Availability | 92 94% | 95 96% | +3 Percentage Points |
| CSS Adjustment Time | Manual process (48 hours downtime)
|
| Oil Change Interval
|
5. TECHNICAL SPECIFICATIONS
Capacity Range: Modeldependent; from 2,500 to over 10,000 metric tons per hour.
Power Requirements: From 450 kW up to 800 kW main drive motor; VFC compatible.
Material Specifications: Main frame & concaves available in various manganese steel alloys; Shaft in highstrength forged steel; Bronze bushings with leadfree alternatives.
Physical Dimensions: Significant footprint savings versus older designs; specific dimensions provided per model quotation.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +50°C (13°F to +122°F). Dust protection rating IP66 standard.
Compliance: Manufactured in accordance with Rohs directives restricting hazardous substances in electrical components.
6. APPLICATION SCENARIOS
Copper Mine Expansion
Challenge: A major copper operation needed to increase primary crushed throughput by 25% without expanding their primary crusher footprint or overloading existing conveyors.
Solution: Implementation of a Rohs Compliant Gyratory Crusher with the HighEfficiency Drive System and optimized liner profile.
Results: Achieved a 28% throughput increase at a finer target product size due to higher reduction efficiency. Energy use per ton decreased by an average of 14%, meeting expansion goals within existing infrastructure constraints.
Granite Aggregate Quarry
Challenge: Unpredictable liner wear led to variable product gradation and frequent production stoppages for mantle changes every six weeks.
Solution: Installation of a midsize Rohs Compliant Gyratory Crusher featuring the Patented Liner Profile and Automated Setting Adjustment System.
Results: Liner life extended consistently to nine weeks while maintaining tighter control on topsize product through remote CSS adjustments during shifts. This resulted in an annual increase of over two weeks of productive runtime.
7. COMMERCIAL CONSIDERATIONS
The Rohs Compliant Gyratory Crusher is offered across three primary capacity tiers—HighProduction (>8k tph), StandardDuty (48k tph), and CompactPrimary (<4k tph)—with pricing structured accordingly based on specifications.
Optional Features: Advanced predictive health monitoring sensors (vibration/temperature), automated tramp iron clearing systems,
spare mainshaft assemblies for rapid changeout programs.
Service Packages: Tiered plans are available from basic preventive maintenance support up to fullsite performance guarantees including parts coverage and dedicated onsite technical support.
Financing Options: Flexible capital equipment financing can be arranged through our partners,
including leasetoown structures that align payments with projected production revenue streams,
helping manage cash flow during capitalintensive projects.
8. FAQ
Q1. Is this gyratory crusher compatible with my existing secondary/tertiary circuit?
Our engineering team conducts full circuit analysis using your current equipment data
to ensure optimal feed size distribution compatibility before any recommendation is made
Q2. What is the typical installation timeline from delivery to commissioning?
For a greenfield site,
allow approximately four months from foundation work through mechanical erection,
electrical tieins,
and commissioning
Brownfield replacements can often be completed faster using preengineered transition plans
Q3. How does this design specifically address maintenance labor costs?
Features like remote setting adjustment,
centralized lube points,
and modular spider/bowl assemblies are engineered specifically
to reduce both timeontool
and required crew size for routine tasks
Q4. Are there financing options that separate machine cost from service packages?
Yes
Capital equipment financing
and operational service agreements are structured separately
This allows you greater flexibility in budgeting capital expenditure versus operational expenditure
Q5. What training is provided for our operations team?
We provide comprehensive operator training focused on daily checks,
the ASAS system,
and basic troubleshooting along with detailed maintenance manuals
for your technical staff
Q6. Can you guarantee performance metrics like throughput or liner life?
Performance guarantees are offered as part of our premium service packages
These are based on agreedupon feed material characteristics
and are contractually defined prior to purchase
Q7. How does Rohs compliance affect longterm parts availability?
Rohs compliance ensures all electrical components will remain globally procurable as environmental regulations tighten It futureproofs your investment against supply chain restrictions