ڪمرشل Gyratory Crusher فئڪٽري
1. PAINPOINT driven اوپننگ
آپريشنل خرچن کي وڌائي رهيا آهن ۽ غير متوقع دستيابي توهان جي بنيادي ڪرشنگ سرڪٽ جي منافعي کي ختم ڪري رهيا آهن? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, the primary crushing stage is a critical bottleneck where inefficiencies cascade through the entire downstream process. Common challenges with commercial gyratory crushers include:
سار سنڀال لاءِ اضافي وقت: روايتي ڊيزائن جي ضرورت آهي ڊگهي, complex procedures for wear part replacement and routine servicing, leading to hundreds of lost production hours annually.
ٽرامپ آئرن کان اڻ رٿيل اسٽاپ: Inadequate protection systems can result in catastrophic damage from uncrushable material, causing repairs that cost upwards of six figures in parts and lost revenue.
متضاد پيداوار جي درجه بندي: Worn or poorly adjusted crushers produce an erratic feed size for secondary circuits, reducing overall plant throughput and recovery rates by 515%.
اعلي توانائي واپرائڻ في ٽون: Older or inefficient gyratory crusher models can consume 1030% more power for the same output, سڌو سنئون توهان جي هيٺئين لائن تي اثر انداز.
Spiraling Liner Replacement Costs & مزدوري: بار بار, laborintensive liner changes with heavy components increase both direct parts expenditure and safety risks for your crew.
ڇا توهان جو آپريشن انهن چئلينجن کي منهن ڏيڻ لاءِ ليس آهي? The right commercial gyratory crusher should be a source of reliability, not recurring cost.
2. پيداوار جو جائزو
جي [ٺاهيندڙ / سيريز جو نالو] is a heavyduty primary gyratory crusher engineered for hightonnage, continuous mining and aggregate operations. It is designed as a longterm asset for fixedplant crushing stations requiring consistent, coarse reduction of runofmine ore or shot rock.
آپريشنل ڪم فلو:
1. کاڌ خوراڪ: وڏا ڊمپ ٽرڪ يا لوڊ ڪندڙ مواد سڌو سنئون کولہو جي مضبوط فيڊ هاپر ۾ جمع ڪن ٿا.
2. ڇڪڻ وارو عمل: مرڪزي مٿاڇري هڪ اسٽيشنري مقبري جي اندر gyrates, applying compressive force to reduce material by pinching and bending against the chamber walls.
3. خارج ٿيڻ: Crushed product exits through the bottom of the crushing chamber (خارج ٿيڻ جو افتتاح) ايندڙ پروسيسنگ اسٽيج تائين ٽرانسپورٽ لاءِ ڪنويئر بيلٽ تي.
ايپليڪيشن جو دائرو:
Ideal for primary crushing of abrasive iron ore, ٽامي جي معدنيات, سون جو ڌاتو, گرينائيٽ, ۽ بيسالٽ. Suited for operations with annual capacities exceeding 1 ملين ميٽرڪ ٽين.
اهم حدون:
Not designed for portable or semimobile applications requiring frequent relocation. Not suitable for recycling or processing materials with very high plastic/clay content that may cause packing.
3. بنيادي خاصيتون
Patented TopService Design | ٽيڪنيڪل بنياد: Integrated maintenance platform & hydraulic shell lifting system | آپريشنل فائدا: Enables all routine maintenance—spider replacement, لينر, countershaft—from above without dismantling the crusher or structure | ROI اثر: منصوبابندي ڪيل سار سنڀال جي وقت تائين گھٽائي ٿي 40%, lowering labor costs and increasing annual available hours.
Intelligent Tramp Iron Protection System | ٽيڪنيڪل بنياد: Hydroset mechanism with pressure sensors & automated release/reset | آپريشنل فائدا: Automatically discharges uncrushable objects by lowering the mainshaft, then resumes operation within minutes without manual intervention | ROI اثر: Prevents an estimated average of $250k+ in potential damage per serious tramp iron event and avoids associated production delays.
ايس ٽي ايل ايف (Straight Tooth Low Profile) Concave Design | ٽيڪنيڪل بنياد: اصلاح ٿيل چيمبر جاميٽري & tooth profile based on DEM (ڌار عنصر ماڊلنگ) تجزيو | آپريشنل فائدا: Delivers more consistent product sizing with fewer fines generation and reduced risk of bridging/choking | ROI اثر: Improves downstream circuit efficiency by providing stable feed; extends liner life by 1520% through even wear distribution.
سڌو ڊرائيو & Torque Limiter | ٽيڪنيڪل بنياد: Vbeltfree design with couplingmounted hydraulic torque limiter | آپريشنل فائدا: Eliminates belt maintenance and slippage; provides precise overload protection for the gear & موٽر | ROI اثر: Reduces power transmission losses by ~3%, توانائي جي ڪارڪردگي کي بهتر بنائڻ; protects major mechanical components from costly damage.
Integrated Smart Chamber Control | ٽيڪنيڪل بنياد: PLCconnected sensors monitoring mainshaft position, دٻاءُ, پاور ڊرا & feed level | آپريشنل فائدا: Allows operators to optimize CSS (بند طرف سيٽنگ) remotely and receive realtime performance alerts | ROI اثر: Maximizes throughput capacity while maintaining product spec; اڳڪٿي واري سار سنڀال جي منصوبابندي کي قابل بڻائي ٿو.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (سراسري) | اسان جي Gyratory کولہو حل | فائدو (% سڌارو) |
| : | : | : | : |
| لائنر جي تبديلي جو وقت (Spider Arm) | 3648 ڪلاڪ | 96% دستاويز ٿيل فيلڊ اوسط| +24 سيڪڙو پوائنٽون |
| توانائي جو واھپو (kWh/tonne) Benchmark varies by material. Comparison based on equivalent duty. Our solution demonstrates measurable reduction against dated designs.| بيس لائين (100%)| Field data shows reduction to ~9093% of baseline| 710% سڌارو |
| ناڪامي جي وچ ۾ وچولي وقت (مکيه اجزاء)| وڏي پيماني تي مختلف آهي; gear failures can occur 10 years for major assemblies under normal duty.| Significant lifecycle extension |
Based on field performance data from installed units in comparable hard rock applications over a 5year period.
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: ماڊل تي منحصر, کان 2,000 ختم ڪرڻ 10,000 ٽين في ڪلاڪ.
فيڊ کولڻ: کان وٺي 1,000 mm تائين 1,500 ايم ايم.
موٽر پاور: عام طور تي وچ ۾ 300 kW ۽ 800 kW depending on model and application.
ڪل وزن: تقريبن کان 150 ٽن کان مٿي 400 ٽين.
مکيه فريم جي تعمير: Highstrength fabricated steel with machined mounting surfaces.
لائنر مواد جا اختيار: Manganese steel standards; optional alloy blends for specific abrasion/impact conditions.
ماحولياتي آپريٽنگ رينج: 40 ° C کان + 50 ° C تائين وسيع گرمي پد لاء ٺهيل; dustproofed bearings and sealed lubrication system standard.
6. درخواست جا منظر
ڪاپر مائن توسيع پروجيڪٽ
چيلنج: An existing mine’s expansion required doubling primary crushing capacity but had limited physical space adjacent to the old crusher station. Downtime during tiein was a critical path item costing over $100k per day.
حل: Installation of a new highcapacity gyratory crusher featuring topservice design was completed in parallel to existing operations. The compact foundation design fit the constrained site.
نتيجا: The tiein outage was reduced from a projected 14 days to just 5 days due to simplified final connections. The new unit achieved nameplate capacity within one week of startup.
گرينائيٽ ڪواري پرائمري سرڪٽ اپ گريڊ
چيلنج: A large aggregate producer faced rising energy costs and excessive liner wear costs on an aging primary gyratory crusher handling highly abrasive granite.
حل: Replacement with a modern gyratory crusher featuring an optimized STLF concave geometry and highefficiency direct drive system.
نتيجا: Annual energy consumption decreased by an estimated 9%. Liner life increased by an average of two weeks per set (~18% improvement), reducing annual liner cost by approximately $65k while maintaining required throughput.
7. تجارتي خيالات
Our commercial gyratory crushers are offered as capital equipment solutions with tiered pricing based on size/capacity model:
بنيادي ٺاھ جوڙ جو درجو: Includes core crusher assembly with standard liners motor drives not included).
آپٽمائزڊ پرفارمنس ٽائر: Base configuration plus smart chamber control system advanced lubrication conditioning monitoring package recommended spare parts kit).
Optional features include custom liner alloys automated lubrication systems specialized tooling kits remote monitoring subscriptions).
We support your investment through:
Service Packages ranging from basic commissioning supervision multiyear comprehensive maintenance agreements including planned inspections parts discounts priority support).
Financing Options available including traditional capital lease operating lease structures tailored project financing can be arranged through our partners facilitate cash flow management).
8. FAQ
What is the typical installation timeline once the unit arrives on site?
For a prepared foundation installation commissioning typically requires weeks depending on model complexity local labor conditions full project scope includes civil works electrical connections).
How does this commercial gyratory crusher integrate with our existing secondary crushing circuit?
The unit is designed produce consistent wellgraded feed modern control systems allow CSS adjustment match downstream requirements interface standard plant PLC/DCS systems via industrial protocols).
What are realistic expectations operational availability?
Based field data similar installations properly maintained units consistently achieve >96% mechanical availability excluding planned maintenance stops external feed interruptions).
What does warranty cover what are typical service intervals?
Standard warranty covers manufacturing defects major components months operation first months whichever comes first key service intervals e.g., lubrication system checks detailed mechanical inspections are outlined maintenance manual often at /hour increments).
Can you provide support training our operations maintenance teams?
Yes comprehensive training conducted during commissioning covers safe operation routine checks basic troubleshooting advanced maintenance procedures also available at our technical centers).
