1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Управление циклом дробления железной руды представляет собой, дорогостоящие проблемы. Are you experiencing persistent bottlenecks that limit your plant’s rated throughput? Are unscheduled maintenance stops and premature wear part failures eroding your operating budget and creating unpredictable downtime? Is inconsistent product sizing leading to inefficiencies in downstream grinding and processing, ultimately affecting pellet or sinter quality? Более того, does the total cost of ownership for your primary crushing stage—factoring in energy consumption, замена вкладышей, and labor—exceed initial projections? These operational hurdles directly impact profitability. Центральный вопрос для руководителей предприятий заключается в следующем.: как можно добиться надежного, hightonnage reduction of abrasive iron ore while controlling operational costs and maximizing plant availability?

2. ОБЗОР ПРОДУКТА

This product is a Первичная вращающаяся дробилка engineered specifically for highcapacity iron ore processing. It is designed as the first critical stage in a mineral processing plant, receiving runofmine (ПЗУ) feed directly from the pit.

Операционный рабочий процесс:
1. Потребление корма: ПЗУ железная руда (размер комка до 1,5 м.) is dumped into the crusher’s deep, незапирающийся приемный бункер.
2. Сокрушительное действие: A centrally mounted mantle gyrates within a concave bowl, applying compressive force to break the ore against itself.
3. Увольнять: Crushed material exits through the bottom setting (CSS), with product size typically ranging from 150mm to 250mm for feed to secondary crushing or SAG mill circuits.

Область применения & Ограничения:
Объем: Ideal for largescale mining operations with high daily tonnage requirements (>10,000 MTD). Suited for processing hard, abrasive hematite and magnetite ores.
Ограничения: Not designed for final product sizing or for processing materials with high clay or moisture content without adequate prescreening/scalping. Требуется стабильный бетонный фундамент и значительная высота для установки и обслуживания..

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Запатентованная вогнутая конструкция | Техническая основа: Сегментированный, reversible alloy steel segments | Операционная выгода: Продлевает срок службы до 30% by allowing rotation and use of multiple wear surfaces before replacement | Воздействие на рентабельность инвестиций: Reduces liner inventory costs and downtime for concave changes

Интегрированное автоматическое регулирование настроек | Техническая основа: Гидравлическая система регулировки с датчиками положения. | Операционная выгода: Allows operators to adjust the crusher discharge setting in minutes without stopping the process | Воздействие на рентабельность инвестиций: Maintains optimal product size for downstream efficiency, increasing overall circuit throughput by an estimated 25%

Система смазки с контролем состояния | Техническая основа: Dualcircuit filtration and temperature/pressure sensors feeding to plant DCS | Операционная выгода: Provides continuous protection of critical bearings; alerts personnel to potential issues before failure occurs | Воздействие на рентабельность инвестиций: Prevents catastrophic bearing damage, a failure that can result in over 200 часы простоя производства

SpiderMounted Dump Hopper & Seal | Техническая основа: Reinforced design with multistage dust seal system | Операционная выгода: Effectively contains dust at the feed point and prevents contaminant ingress into the main bearing assembly | Воздействие на рентабельность инвестиций: Reduces environmental emissions compliance costs and extends bearing life in dusty conditions

Конструкция главного вала для тяжелых условий эксплуатации | Техническая основа: Forged alloy steel shaft with optimized fatigue resistance profile | Операционная выгода: Provides exceptional strength to handle tramp steel and uncrushable material events without shaft deflection or failure | Воздействие на рентабельность инвестиций: Eliminates unplanned outages related to shaft failure, a primary cause of extended downtime in primary crushing

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт (Средние показатели конкурентов) | This Primary Gyratory Crusher Solution | Преимущество (% Улучшение) |
| : | : | : | : |
| Доступность (Запланированное время выполнения) | 9294% | 96%+ documented field average over 24 месяцы | ~34 % улучшение |
| Лайнер Жизнь (Million Tons/Set) Hematite Ore| 4.5 5.5 тонн | 6.0 7.0 тонн verified at multiple sites| ~1520% улучшение |
| Удельное энергопотребление (кВтч/тонна) | 0.18 0.22 кВтч/т | 0.15 0.17 кВтч/т based on installed motor vs. throughput data| ~18% улучшение |
| Tramp Iron PassThrough Recovery Time| Ручная очистка; часы простоя| Hydraulic clearing system; 80% reduction in event duration |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Обозначение модели: PGC60110
Кормовое отверстие: 1,520 мм (60 дюймы)
Номинальный диапазон производительности: 3,500 7,500 м/ч (dependent on ore characteristics and discharge setting)
Установленная мощность: 600 кВт (800 HP) electric drive motor
Главный вал: Forged ES355 alloy steel
Вогнутый & Mantle Material: ASTM A128 Manganese Steel with proprietary heat treatment
Общий вес (Только дробилка): ~275 metric tons
Top Shell Diameter: ~4.8 meters
Диапазон рабочих температур: 30°С до +45°С (with appropriate lube oil specifications)
Контроль пыли: Integral connection points for plant dust extraction system.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

LargeScale Open Pit Mine – Australia Challenge:

A major hematite operation faced declining feed grades, requiring higher throughput volumes through their primary crushing station to maintain annual production targets. Their existing crusher was unable to achieve higher tonnage without excessive wear and energy costs.

Решение:

Implementation of one PGC60110 Primary Gyratory Crusher with the integrated automatic setting system.

Результаты:

Within six months of commissioning:
Sustained throughput increased by 18%, meeting upgraded plant demands.
Energy cost per ton crushed decreased by 16%.
Annual planned maintenance hours were reduced by 120 hours due to extended liner intervals.

Magnetite Concentrator – North America Challenge:

The client’s new greenfield project required a primary crusher capable of handling extremely hard magnetite ore while guaranteeing >95% availability as the single point of failure for the entire coarse ore circuit.

Решение:

Installation of two PGC60110 crushers configured with full condition monitoring on lube systems and main bearings.

Результаты:

Over the first two years of operation:
Achieved an average operational availability of 96.7%.
Successfully passed multiple tramp metal events without damage via the hydraulic release system.
Condition monitoring provided actionable data that allowed scheduling of a bearing inspection during a planned plant shutdown, avoiding a predicted inservice failure.

7 КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Our commercial model is structured around providing predictable total cost outcomes.

Ценовые уровни оборудования: Pricing is based on configuration.
Базовая конфигурация: Core crusher assembly with standard lubrication unit.
Расширенная конфигурация: Includes automatic setting regulation (АСР), усовершенствованные датчики мониторинга состояния, and upgraded dust sealing.
Turnkey SkidMounted Unit: Crusher preassembled on a structural skid base with walkways, лестницы, and integrated lubrication system for faster installation.

Дополнительные функции & Обновления: Wear monitoring systems via concave wear sensors; premium ceramic composite liners for specific abrasion zones; custom discharge conveyor flanges; extended warranty packages on major castings.

Пакеты услуг:
Соглашение о плановом техническом обслуживании: Плановые проверки, oil analysis programs, и техническая поддержка.
Liner Service Contract: Guaranteed liner life performance with fixedcostperton replacement parts.
Контракт на полное обслуживание: Охватывает все части (носить & механический), труд, and field service engineering for a fixed annual fee.

Варианты финансирования: We offer several capital solutions including traditional equipment financing/leasing through our partners or performancebased contracting models where payments can be partially linked to achieved availability or throughput guarantees.

8 Часто задаваемые вопросы

1.Q What is the lead time from order placement to delivery?
A For standard models like the PGC60110 lead times are typically between 912 months due to extensive forging and machining requirements for major components like the main shaft and top shell castings

2.Q How does this crusher integrate with our existing PLC/SCADA control system?
A The unit comes standard with an AllenBradley ControlLogix PLC local panel All critical operational data pressure temperature motor status ASR position are communicated via industrystandard Modbus TCP/IP or Ethernet/IP protocols allowing straightforward integration into your wider plant control network

3.Q What are your recommendations regarding feed size distribution?
A For optimal performance we recommend ROM feed where no more than XNUMX% exceeds XNUMX times the nominal feed opening size Consistent feeding using a vibrating grizzly feeder or apron feeder is critical Our engineering team can review your specific mine plan geology data

4.Q Do you provide installation supervision?
A Yes we offer optional expert field service supervision during installation commissioning This service ensures correct mechanical alignment electrical connection verification lubrication system flushing procedure adherence which directly impacts longterm reliability

5.Q What are typical spare parts inventory recommendations?
A We provide sitespecific recommendations based on your operating schedule However we maintain regional stockholding centers globally offering XNUMX/XNUMX emergency parts dispatch Critical spares like main shaft step washers eccentric bushings should be held onsite per our recommended list

6.Q Can you guarantee performance metrics like capacity or liner life?
A Formal performance guarantees are provided as part of our commercial proposal following detailed review analysis of your representative ore samples geotechnical data These guarantees form part binding contract subject defined test protocols postcommissioning