1. PAINPOINT DRIVEN OPENING

Are your sand and gravel mining operations constrained by inconsistent feed, excessive fines generation, and escalating maintenance costs? Inconsistent particle size distribution from your primary crushing stage directly impacts the efficiency of your entire processing plant, leading to bottlenecks in screening and material handling. Unplanned downtime for liner changes and component wear in abrasive environments translates to significant lost production revenue. Furthermore, inefficient reduction ratios force secondary crushers to work harder, increasing power consumption and operational expense.

Are you facing these challenges?
How much production is lost annually due to crusher maintenance and adjustment downtime?
What is the true cost of premature wear parts in your highly abrasive feed material?
Could a more consistent product from primary crushing improve your overall plant throughput and product yield?

2. PRODUCT OVERVIEW: PRIMARY GYRATORY CRUSHER FOR SAND & GRAVEL

The solution to these core challenges is a heavyduty primary gyratory crusher engineered specifically for hightonnage sand and gravel mining. This equipment serves as the first critical stage of size reduction, processing runofquarry material into a manageable feed for downstream circuits.

Operational Workflow:
1. Feed Intake: Dump trucks or loaders deposit large (up to 1500mm) quarried rock directly into the crusher’s deep, nonchoking receiving hopper.
2. Continuous Crushing: The central gyrating mantle compresses material against the stationary concave liners, applying progressive compression to break rock along natural fracture lines.
3. Discharge Setting: Crushed material exits through the adjustable bottom setting, determining the primary product size, typically between 150mm and 250mm.
4. Material Transfer: The crushed product is conveyed to subsequent stages for secondary crushing, screening, and classification.

Application Scope & Limitations:
Scope: Ideal for highcapacity (5,000+ TPH) greenfield sites or expansion projects requiring reliable primary reduction of hard, abrasive aggregates like granite, trap rock, and limestone.
Limitations: Not suitable for lowtonnage operations (< 1,000 TPH) due to capital cost and physical footprint. Requires a stable concrete foundation and significant installation planning.

3. CORE FEATURES

Patented NonChoking Profile & Deep Chamber | Technical Basis: Optimized feed opening geometry and chamber depth | Operational Benefit: Eliminates bridging and ensures continuous flow of large, slabby feed material without prescreening | ROI Impact: Reduces loader idle time by up to 15% and prevents costly flow stoppages.

Integrated Automatic Setting Regulation (ASR) System | Technical Basis: Hydraulic adjustment with realtime position sensors | Operational Benefit: Allows operators to adjust discharge setting under load in under one minute for precise product size control | ROI Impact: Maintains target spec yield; eliminates 23 hours of downtime per manual adjustment cycle.

Liner Lifetime Optimization Design | Technical Basis: Computermodeled crushing chamber kinematics and highstrength alloy steel castings | Operational Benefit: Distributes wear evenly across concave segments and mantle, extending service life in abrasive applications | ROI Impact: Reduces liner replacement frequency by 2030%, lowering part costs and planned downtime.

HighCapacity Lubrication & Dust Sealing | Technical Basis: Positivepressure labyrinth seals with dedicated grease purging circuit | Operational Benefit: Effectively excludes abrasive dust from critical bearings and internal mechanisms | ROI Impact: Extends major bearing service intervals by thousands of hours, preventing catastrophic failure.

LowSpeed HighTorque Drive System | Technical Basis: Direct Vbelt drive or lowspeed synchronous motor coupled to heavyduty gear set | Operational Benefit: Delivers maximum crushing force at startup and through tough inclusions with minimal stress spikes | ROI Impact: Reduces belt slippage/breakage events; lowers specific energy consumption per ton crushed by an average of 8%.

Remote Monitoring & Diagnostics Interface | Technical Basis: Standardized industrial IoT gateway for key parameters (power draw, oil temp/pressure, bearing vibration) | Operational Benefit: Provides plant managers with predictive maintenance alerts and operational performance dashboards from the control room | ROI Impact: Enables conditionbased maintenance planning to avoid unplanned stops.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Jaw Crusher Primary) | Gyratory Crusher Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability / Uptime | 8590% (frequent liner/wedge adjustments) | 9396% (longer wear life, adjustunderload) | +7% Availability |
| Operating Cost per Ton (Wear Parts)| $0.45 $0.60/ton processed| $0.32 $0.42/ton processed| 25% Cost Reduction |
| Specific Energy Consumption| Higher due to reciprocating motion & lower throughput| Lower kWh/ton due to continuous action & higher efficiency| 8% Energy Use |
| Feed Size Capability / Throughput| Limited by nip angle; lower TPH for same feed size| Accepts larger feed at higher hourly tonnage rates| +30% Throughput Capacity |
| Labor for Routine Adjustments| Manual shim adjustment requires crew & downtime (<4 hrs)| Hydraulic ASR system adjustment (<1 min), operatoronly task.| 99% Adjustment Time |

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Configurable from 3,500 to over 10,000 metric tons per hour (MTPH), depending on model selection.
Feed Opening: Gape sizes from 1,200mm to 1,500mm standard.
Power Requirements: Main drive motor ranging from 450 kW to 800 kW (600 HP – 1100 HP). Auxiliary lube system requires separate power supply.
Material Specifications: Mantle & concaves manufactured from Mn18Cr2 or equivalent premium abrasionresistant steel. Main shaft forged from highstrength alloy steel.
Physical Dimensions / Footprint: Approximate installed diameter of 6m – 8m; total height of ~5m – 6m excluding feed hopper.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C with appropriate oil specifications. Dusttight construction meets IP65 standards.

6. APPLICATION SCENARIOS

LargeScale Granite Aggregate Producer Challenge:

A major Southeast US aggregate plant needed to increase primary circuit throughput by over 25% while reducing liner change frequency in highly abrasive granite.

Solution:

Implementation of a largecapacity gyratory crusher with advanced chamber profiles replaced two parallel jaw crushers.

Results:

Throughput increased by 32%. Liner life extended from ~600k tons to ~850k tons per set (29% consumption). Overall plant availability improved due to reduced primary stage bottlenecks.

Alluvial Gravel Processing Expansion Challenge:

A Midwestern operator processing riverrun gravel faced constant bridging issues in their old primary jaw crusher with variable clay content.

Solution:

Installation of a deepchamber nonchoking gyratory crusher designed for sticky feed conditions.

Results:

Bridging events eliminated entirely. Plant was able to process higher claycontent deposits without prescreening/scalping washdowns (18 minutes/hour lost time). Product consistency improved downstream screening efficiency by an estimated 12%.

7. COMMERCIAL CONSIDERATIONS

Equipment Pricing Tiers: Capital investment ranges significantly based on capacity ($2M $5M USD). Highertier models include integrated automation packages as standard.
Optional Features / Upgrades: Key options include advanced alloy liners (+1520% cost), automated lubrication systems (+$50k), full IoT predictive analytics suite (+$75k$100k), custom discharge conveyor flanges/fittings (+$10k).
Service Packages: Annual inspection contracts (~23% of CAPEX/year). Comprehensive multiyear wear part/service bundles offer predictable costperton pricing (~1015% savings vs spot purchasing).
Financing Options: Manufacturerbacked leasing structures are available with terms up to seven years tailored for large capital projects; traditional bank financing support can be facilitated through partner institutions.

8. FAQ

Q1. Is a gyratory crusher compatible with our existing secondary cone crushers?
A. Yes; it provides an ideal firststage reduction ratio that optimizes the load on secondary circuits—producing a more consistent feed size that improves overall plant balance.

Q2. What is the typical installation timeframe?
A. From foundation readiness commissioning requires approximately eight weeks—including mechanical erection electrical tieins controls integration dry testing wet commissioning

Q3. How does this impact our overall site power demand?
While individual motor draw is significant field data shows that improved overall plant flow efficiency often results in net lower specific energy consumption per ton final product

Q4. What are standard payment terms?
Standard commercial terms are thirty percent down payment upon order sixty percent upon shipment readiness ten percent upon commissioning Letter Credit arrangements are common

Q5. What training is provided operators maintenance staff?
Comprehensive onsite training conducted over five days covers safe operation routine maintenance procedures troubleshooting diagnostics using remote tools

Q6. Can we supply our own liners other wear parts?
Warranty coverage requires use genuine OEM parts Performance longevity claims are based on specified metallurgy dimensional tolerances

Q7. How does equipment handle uncrushable tramp metal
All models incorporate hydraulic overload protection system that automatically opens discharge setting release tramp metal then returns previous setting without stopping machine