Export Gyratory Crusher Specification
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 processing line. عام چئلينج شامل آهن:
اڻ شيڊول بند وقت: Premature wear of critical components like mantles and concaves leads to frequent, disruptive stoppages for replacement, costing hundreds of production hours annually.
هاء PerTon آپريٽنگ خرچ: Excessive energy consumption per crushed tonne and the high cost of consumable parts directly impact your bottomline operating expenditure.
متضاد پيداوار جي درجه بندي: Fluctuations in feed material can cause significant variation in product size, overloading downstream screens and crushers, reducing overall plant throughput.
LaborIntensive Maintenance: Traditional designs require extensive manual intervention for setting adjustments and wear part inspection, exposing personnel to risk and extending maintenance windows.
Is your operation equipped to handle increasing ore hardness and throughput demands while controlling costs? The specification of your primary gyratory crusher is the foundational decision that determines longterm circuit stability and economic performance.
2. پيداوار جو جائزو: گيريٽري ڪرشر
A gyratory crusher is a stationary compressive crushing machine central to hightonnage mining and aggregate operations. It reduces runofmine ore or large quarry rock by compressing it between a fixed concave surface and a gyrating mantle mounted on an oscillating spindle.
آپريشنل ڪم فلو:
1. کاڌ خوراڪ: Largesized material is directed into the top of the crusher’s crushing chamber via a feed hopper.
2. Compressive Crushing: The central shaft assembly (مکيه شافٽ, چادر) gyrates within the stationary concave liner. Rock is nipped and crushed as it moves downward through the progressively narrower chamber.
3. Discharge Setting Control: The final product size is determined by the closedside setting (سي ايس ايس), adjusted by raising or lowering the main shaft assembly hydraulically.
4. پيداوار جي خارج ٿيڻ: ڪرش ٿيل مواد کولہو جي تري مان نڪرندو آهي (the discharge opening) onto a conveyor for transport to secondary processing.
ايپليڪيشن جو دائرو & حدون:
دائرو: سخت جي ابتدائي ڪٽڻ لاء مثالي, ٻرندڙ معدنيات (لوهه, ٽامي, سون) and large aggregate feed in highcapacity operations (>1,000 tph). Excels in slabby material handling.
حدون: Higher capital cost compared to equivalent jaw crushers. Requires a substantial, stable foundation. گھٽ ٽوننج آپريشنز لاءِ مناسب نه آھي يا تبديليءَ کانسواءِ انتهائي پلاسٽڪ/چپچپا مواد.
3. بنيادي خاصيتون
Patented Concave Design | ٽيڪنيڪل بنياد: Segmented, alloyoptimized liner profiles | آپريشنل فائدا: Extended service life up to 30% longer than conventional designs; more uniform wear distribution | ROI اثر: Reduces liner inventory costs and downtime frequency for changes
Integrated Smart Control System | ٽيڪنيڪل بنياد: Realtime sensors monitoring power draw, دٻاءُ, سي ايس ايس, and wear | آپريشنل فائدا: Provides predictive analytics for maintenance scheduling; prevents overload damage; optimizes throughput automatically | ROI اثر: Minimizes catastrophic failure risk; پيداوار جي تسلسل کي بهتر بڻائي ٿو; reduces unplanned downtime by up to 25%
HeavyDuty Quill Shaft Drive | ٽيڪنيڪل بنياد: Direct geardriven transmission with hightorque capability | آپريشنل فائدا: Delivers consistent power transfer with higher mechanical efficiency than Vbelt drives; handles tramp metal events with less risk of stall | ROI اثر: Lower energy consumption per tonne; reduced drive system maintenance costs
خودڪار سيٽنگ ايڊجسٽمينٽ سسٽم (ASRi) | ٽيڪنيڪل بنياد: Hydraulic ram system controlled via PLC with continuous position feedback | آپريشنل فائدا: Allows operators to adjust CSS remotely under load in minutes for precise product size control | ROI اثر: انسپيڪ پراڊڪٽ جي پيداوار کي وڌايو; eliminates hours of manual adjustment work
Spiderless Design Option | ٽيڪنيڪل بنياد: Eliminates the traditional spider bridge at the top of the crusher | آپريشنل فائدا: محفوظ مهيا ڪري ٿو, unobstructed access to all service points from above; significantly simplifies mantle changeout procedures | ROI اثر: Cuts scheduled maintenance time by up to 50%, directly increasing annual available operating hours
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري معيار | اسان جي Gyratory کولہو حل | دستاويزي فائدو |
| : | : | : | : |
| دستيابي (Annual Operating Hours) | ~92% (67% بند وقت) | >95% (<5% بند وقت)| +35% سڌارو |
| توانائي جي ڪارڪردگي (kWh/tonne) مواد جي لحاظ کان مختلف آهي| بيس لائين = 100%| تي ماپيل 8590% بنيادي طور تي| 1015% گھٽتائي |
| لائنر جي تبديلي جو وقت (ڪلاڪ)| 24 48 ڪلاڪ| 12 24 ڪلاڪ| تائين 50% تيز |
| Total Cost per Tonne (5year TCO)| بيس لائين = 100%| Typically achieves 7585% بنيادي قيمت جي| 1525% Lower TCO |
5. ٽيڪنيڪل وضاحتون
ظرف & درجه بندي: Modeldependent capacities from 2,000 ختم ڪرڻ 10,000 ٽين في ڪلاڪ (tph). Designed for feed sizes up to 1500mm.
بجلي جي گهرج: Main motor ratings from 300 kW تائين 800+ ڪلواٽ. Voltage as per client specification (مثال, 6.6 kV). Complete electrical control package included.
مواد جي وضاحت: مکيه فريم اعلي طاقت اسٽيل پليٽ مان ٺهيل. Critical wearing parts (ڪپڙا, مقدر) available in premium manganese steel alloys or composite metal matrix materials for specific abrasion/impact conditions.
جسماني طول و عرض & وزن: Significant footprint requiring engineered concrete foundation. Approximate weights range from ~150 tonnes for smaller models to over 500 tonnes for largest units.
ماحولياتي آپريٽنگ رينج: مناسب لوبريڪيشن سسٽم سان گڏ 40 ° C کان + 50 ° C تائين محيطي درجه حرارت لاء ٺهيل. Dust sealing systems standard.
6. درخواست جا منظر
وڏي پيماني تي ڪاپر مائن جي توسيع
چيلنج: A tierone copper operation needed to increase primary circuit throughput by 20% without expanding its footprint or overhauling downstream conveyors. Existing equipment was at capacity limits with frequent liner wear issues.
حل: Implementation of a highcapacity gyratory crusher featuring our advanced concave design and smart control system was specified.
نتيجا: جي ذريعي وڌي ويو 22%. Liner life improved by an average of 28%, reducing annual planned stoppages from four to three. The smart system optimized power use during variable ore hardness periods.
HighAbrasion Aggregate Quarry
چيلنج: A granite quarry faced unsustainable consumable costs and excessive vibration transmitted to foundations due to highly abrasive feed material causing uneven wear patterns.
حل: A robustly built gyratory crusher with a specialized metal matrix concave package was installed alongside an enhanced base frame damping system.
نتيجا: Total cost per tonne for consumables decreased by approximately18%. Foundation stress was measurably reduced through improved load distribution.
7. تجارتي خيالات
Our gyratory crushers are offered across several tiers:
معياري ڊيوٽي جي حد: For consistent feed materials in large aggregate applications.
ڳري ڊيوٽي / Mining Range: Engineered for maximum availability in continuous hardrock mining service with premium component specifications.
اختياري خاصيتون شامل آهن:
Advanced dust suppression systems
Automated lubrication units
Comprehensive condition monitoring packages
Spiderless design configuration
We provide structured service agreements from basic preventive maintenance support upto fullsite performance contracts guaranteeing uptime metrics.
Flexible financing options are available including capital purchase models as well as longterm leasetoown agreements designed around project cash flow requirements.
FAQ
1\. How does this gyratory crusher integrate with our existing secondary crushing circuit?
The unit’s automated setting control system can be networked with your plant SCADA/DCS system allowing realtime adjustment based on downstream feedback ensuring optimal chokefed operation without overloading subsequent stages.
2\. What is required during installation regarding foundation preparation?
Detailed civil engineering drawings specifying reinforced concrete foundation mass dimensions reinforcement requirements anchor bolt placement are provided well aheadof delivery Our field engineers supervise installation ensuring compliance
3\. Can you quantify typical operational training requirements?
Field data shows that comprehensive operator training program covering daily checks basic troubleshooting lasts approximately three days Maintenance team trainingfor major wear part replacement requires fivetoseven days depending on crew experience level
4\. What are standard payment terms lead times?
Standard commercial terms involve progress payments tiedto key manufacturing milestones Lead times varyby model complexity typically rangingfrom eight monthsfor standard configurationsto fourteen monthsfor fully customized units subjectto current foundry capacity
5\. How does warranty coverage work?
We offera standard warranty covering defectsin materials workmanshipfor twelve monthsfrom commissioning Extended warranty coverageis availablefor major structural componentsand canbe bundledwithservice agreements
