Gyratory Crusher Factories R&ڊي
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. اهم چئلينج شامل آهن:
اڻ شيڊول بند وقت: Premature failure of critical components like mainshafts or concaves leads to production halts costing tens of thousands per hour in lost throughput.
گھڻي سار سنڀال جا خرچ: بار بار, laborintensive liner changes and unpredictable wear life consume maintenance budgets and divert skilled personnel from other critical tasks.
غير مطابقت واري پيداوار جي ماپ: Poor feed distribution or worn crushing chambers yield an inconsistent feed for secondary circuits, مجموعي پلانٽ جي ڪارڪردگي ۽ حتمي پيداوار جي معيار کي گهٽائڻ.
اعلي توانائي واپرائڻ: Inefficient crushing action and outdated drive systems result in unsustainable power draw, سڌو سنئون توهان جي هيٺئين لائن تي اثر انداز.
محدود فيڊ لچڪدار: Inability to handle varying ore hardness or occasional tramp metal without causing significant damage.
ملڪيت جي ڪل قيمت کي سنڀالڻ دوران توهان وڌيڪ اعتماد سان اعليٰ ذريعي ڪيئن حاصل ڪندا آهيو? The answer lies in advanced gyratory crusher design focused on durability, intelligence, ۽ ڪارڪردگي.
2. پيداوار جو جائزو: HEAVYDUTY پرائمري GYRATORY Crusher
This heavyduty primary gyratory crusher is engineered for the first stage of comminution in hightonnage mining and aggregate operations. It is designed to accept runofmine feed directly from haul trucks, مسلسل پهچائڻ, coarse product to downstream conveying and processing systems.
آپريشنل ڪم فلو:
1. فيڊ جي قبوليت: Direct dump from haul trucks into the rugged feed hopper, guided by a onepiece spherical spider cap for optimal entry.
2. ڇڪڻ وارو عمل: The eccentrically mounted mainshaft gyrates within the concave liners, applying compressive force to reduce large rock (often +1m) قابل انتظام سائيز تائين.
3. پيداوار جي خارج ٿيڻ: Crushed material exits through the discharge opening at the bottom of the crushing chamber, dictated by the selected crusher setting (سي ايس ايس).
ايپليڪيشن جو دائرو & حدون:
دائرو: اعلي ظرفيت لاء مثالي (5,000 15,000+ tph) primary crushing of abrasive hard rock (لوهه, ٽامي جي معدنيات, گرينائيٽ), چونا پٿر, and other minerals. مقرر ٿيل پلانٽ تنصيب لاء مناسب.
حدون: Not designed for portable plants or lowtonnage operations (< 500 tph). اهم سرمائي سيڙپڪاري ۽ مضبوط ڪنڪريٽ بنياد جي ضرورت آهي. Less effective on clayrich or highly plastic materials that may cause packing.
3. بنيادي خاصيتون
Patented Concave ڊيزائن | ٽيڪنيڪل بنياد: ورهايل, alloyoptimized liner system with mechanical locking | آپريشنل فائدا: تائين جي بدلي جي گھٽتائي کي گھٽائي ٿو 40% versus bolted designs; allows mixing liner profiles for optimal chamber geometry | ROI اثر: Lower labor costs per changeout and maximized liner utilization increase annual available crushing hours.
Integrated Intelligent ڪنٽرول سسٽم | ٽيڪنيڪل بنياد: Realtime sensors monitoring pressure, گرمي پد, پاور ڊرا, and wear | آپريشنل فائدا: Provides predictive analytics for maintenance scheduling and alerts operators to abnormal conditions like bridging or overload | ROI اثر: تباهي واري ناڪامي کي روڪي ٿو; enables conditionbased maintenance over scheduled intervals.
Hydroset® Tramp ڇڏڻ & سي ايس ايس ايڊجسٽمينٽ | ٽيڪنيڪل بنياد: Hydraulic piston supporting the mainshaft for remote adjustment of the Closed Side Setting (سي ايس ايس) | آپريشنل فائدا: Allows quick compensation for wear or product size changes without stopping the crusher; خود بخود ٽرام لوھ جاري ڪري ٿو | ROI اثر: پيداوار جي خاصيت جي استحڪام کي برقرار رکي ٿو; protects internal components from damage by uncrushables.
HighPrecision Spiral Bevel Gear & پنون | ٽيڪنيڪل بنياد: Computermodeled gear geometry manufactured to AGMA 14 معيار | آپريشنل فائدا: Ensures smooth power transmission with minimal vibration and noise; extends gear life significantly under hightorque loads | ROI اثر: Reduces risk of catastrophic drive system failure; lowers longterm spare parts inventory cost.
مرڪزي خودڪار لوبريڪيشن | ٽيڪنيڪل بنياد: Programmable system delivering precise oil volumes to key bearings at set intervals | آپريشنل فائدا: دستي لوڻ جي غلطي کي ختم ڪري ٿو; ensures optimal bearing temperature and longevity even in dusty environments | ROI اثر: ناڪامين جي وچ ۾ سڌو سنئون وقت وڌائي ٿو (ايم بي ايف) for critical bearings; reduces lubricant consumption.
Robust Mainshaft & Head Center Design | ٽيڪنيڪل بنياد: Forged from highstrength alloy steel with precision machining on bearing journals | آپريشنل فائدا: Provides exceptional resistance to bending fatigue and shock loads from oversized feed | ROI اثر: The core component's extended lifecycle defers major capital overhaul expenses for years.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري معيار | اسان جي Gyratory کولہو حل | دستاويزي فائدو |
| : | : | : | : |
| لائنر جي تبديلي جو وقت (ميجر) | 48 72 ڪلاڪ | 24 36 hours with tooling package| ~ 50٪ گهٽتائي |
| آپريشنل دستيابي (سالياني) | 92 94%| >96% (with Intelligent Control System)| +24 سيڪڙو پوائنٽون |
| مخصوص توانائي واپرائڻ (kWh/t) مواد جي لحاظ کان مختلف آهي.| بيس لائين = 100%| جي سراسري گهٽتائي 58% بهتر ڪيل ڪينيميٽيڪس ذريعي & ڊرائيونگ جي ڪارڪردگي| ~ 7٪ واڌارو |
| Wear Life of Concaves (اباڻڻ وارو اٽو) MTons/Set| Varies widely by ore.| فيلڊ ڊيٽا جي مسلسل بهتري ڏيکاري ٿي 1525% via material science & design.| ~20% increase |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: مان ترتيب ڏيڻ وارا ماڊل 3,000 ختم ڪرڻ 15,000 ميٽرڪ ٽين في ڪلاڪ (tph), فيڊ جي مواد تي منحصر آهي ۽ بند ٿيل سيٽنگ.
موٽر پاور: Electric drive options from 450 kW تائين 1,200 ڪلواٽ (600 1,600 ايڇ پي). Dual pinion drives available for highest horsepower models.
فيڊ کولڻ: گپ سائيز کان 1,300 mm تائين 1,800 ايم ايم (54" جي طرف 72").
اهم مواد جي وضاحت: Main frame of fabricated hightensile steel; concaves in manganese steel or optional alloy composites; mainshaft forged from NiCrMo alloy steel.
جسماني طول و عرض / وزن: Approximate total installed weight ranges from 400 ٽن کان مٿي 800 tonnes ماڊل جي ماپ تي منحصر ڪري ٿو. Foundation forces are provided for detailed civil engineering.
ماحولياتي آپريٽنگ رينج: 40 ° C کان + 50 ° C تائين وسيع گرمي پد لاء ٺهيل. Dust seals and pressurized housing options available for extreme environments.
6. درخواست جا منظر
وڏي پيماني تي ڪاپر مائن جي توسيع
Challenge A tierone copper miner required a primary crusher solution for a new pit expansion capable of processing highly abrasive sulfide ore at >10,000 tph while minimizing planned downtime.
Solution Installation of a superduty gyratory crusher featuring our patented concave system and intelligent controls.
Results Achieved sustained throughput of 10,500 tph. Liner life increased by an average of 22%, reducing planned changeouts from three to two per year. The control system predicted a bearing anomaly months in advance, allowing planned intervention during a conveyor shutdown.
اعلي پيداوار گرينائيٽ کوٽ
Challenge An aggregate producer needed consistent (8 انچ) product size for their rail loadout facility but faced bottlenecks due to frequent maintenance on older equipment.
Solution Replacement with a midsize gyratory crusher equipped with Hydroset® automation.
Results CSS adjustments are now made remotely in minutes versus hours of manual work. Product consistency improved such that secondary cone crusher throughput increased by an estimated 9%. Annual maintenance hours decreased by 30%.
7. تجارتي خيالات
Our gyratory crushers are offered under a transparent commercial framework designed for longterm partnership:
سامان جي قيمت جا درجا: Pricing is modelspecific based on size/capacity. Standard packages include crusher assembly motor drive auxiliary lubrication unit basic controls foundation drawings
اختياري خاصيتون & واڌارو: Intelligent Control System premium wear material packages automated mantle positioning tool automated lubrication system special environmental sealing kits
سروس پيڪيجز دستياب
Basic Warranty covers defects in materials/workmanship
Extended Service Agreement includes scheduled inspections parts discounts technical support
Full Performance Contract guaranteed availability wear part consumption service crew support
Financing Options We work with leading industrial finance providers to offer competitive leasing longterm rental or purchase plans tailored to your capital expenditure cycles
8.FAQ
Q What infrastructure is required prior installation?
A A reinforced concrete crusher foundation designed per our supplied load drawings is mandatory Access for heavy lift cranes during installation/maintenance must be considered Electrical substation capacity must match motor requirements
Q How does this integrate with our existing PLC/SCADA system?
A The crushers intelligent control system communicates via standard industrial protocols OPC UA Modbus TCP/IP providing key data points health status alarms It can function as standalone unit interface seamlessly
Q What is typical lead time delivery?
A Lead times vary by model complexity current manufacturing load Standard models typically have lead time months Custom configurations may require additional time Detailed schedule provided upon project initiation
Q Are training operator manuals provided?
A Yes comprehensive training program conducted at your site covers safe operation routine maintenance basic troubleshooting Detailed digital paper manuals parts books are supplied standard
Q Can you supply compatible downstream equipment conveyors bins?
A While we specialize primary crushing equipment we can provide interface specifications coordinate with preferred partners ensure complete circuit compatibility through project engineering phase
