Premium Limestone Mining Supplier
1. PAINPOINT driven اوپننگ
Managing a limestone quarry or processing plant presents distinct, قيمتي چئلينج. Are you experiencing persistent bottlenecks that limit your operation’s true capacity? عام درد جون پوائنٽون شامل آهن:
Excessive Primary Crusher Downtime: Bridging and clogging at the primary crushing stage due to oversized, slabby feed material halts entire production lines, ھزارين في ڪلاڪ جي خرچ ۾ گم ٿي وڃڻ.
Unpredictable Feed Size to Downstream Processes: Inconsistent fragmentation from the muck pile leads to poor crusher performance, increased wear on conveyor systems, and inefficient sizing for kiln feed or aggregate products.
High Operational Costs from Secondary Breakage: Reliance on hydraulic hammers for secondary breaking is laborintensive, slow, and incurs substantial costs in tool wear, ٻارڻ, and equipment maintenance.
Safety and Vibration Concerns: Secondary breaking and inefficient primary blasting can generate excessive ground vibration, posing regulatory compliance risks and community relation issues near sensitive boundaries.
مرڪزي سوال آهي: how can you achieve a consistently fragmented, optimally sized feed from the face to your primary crusher to maximize plant uptime and reduce downstream processing costs?
2. پيداوار جو جائزو
The solution is a highcapacity Primary Gyratory Crusher engineered specifically for hightonnage limestone mining operations. This equipment serves as the cornerstone of your raw material handling system, designed to accept runofquarry limestone directly from the haul trucks.
آپريشنل ڪم فلو:
1. Direct dump of shot limestone from haul trucks (up to 2meter top size) into the crusher’s large feed hopper.
2. The gyrating mantle within the fixed concave crushes material via compressive force, reducing it by a factor of 6:1 جي طرف 8:1.
3. Crushed product discharges onto the main plant conveyor at a consistent size (عام طور تي <250ايم ايم), ready for secondary crushing or screening.
ايپليڪيشن جو دائرو: Ideal for largescale quarry operations with annual production exceeding 1 million tons. It is designed for continuous, 24/7 operation under heavy load.
حدون: Not suitable for smallscale quarries or portable crushing setups due to significant foundation requirements and capital investment. Requires consistent, planned maintenance shutdowns.
3. بنيادي خاصيتون
Patented NonChoking Concave Profile | ٽيڪنيڪل بنياد: Steepsided feed opening with optimized curvature | آپريشنل فائدا: Eliminates bridging of slabby limestone; ensures continuous material flow even with high clay content | ROI اثر: Reduces crusher stall events by up to 90%, directly increasing available crushing hours
ضم ٿيل خودڪار سيٽنگ ريگيوليشن (ASR) سسٽم | ٽيڪنيڪل بنياد: Hydropneumatic adjustment with realtime position sensors | آپريشنل فائدا: Maintains target discharge setting without manual intervention; compensates for mantle wear automatically | ROI اثر: Delivers consistent product sizing (+/ 5% tolerance), improving downstream efficiency and reducing product waste
HeavyDuty Main Shaft & Spider Assembly | ٽيڪنيڪل بنياد: Forged alloy steel shaft with premium bronze bushing design | آپريشنل فائدا: Withstands extreme shock loads from uncrushable material; provides reliable service life exceeding 10 years in abrasive limestone | ROI اثر: Lowers lifetime cost of ownership via extended major component life and reduced risk of catastrophic failure
Lube System with Dual Coolers & Filtration | ٽيڪنيڪل بنياد: Redundant cooling circuits and offline filtration unit | آپريشنل فائدا: Maintains optimal bearing temperature in highambient conditions; continuously purges contaminants from oil | ROI اثر: Extends bearing service intervals by up to 50%, decreasing lubrication costs and unplanned downtime
Smart Chamber Design & Wear Monitoring | ٽيڪنيڪل بنياد: Modular concave segments with embedded wear sensors | آپريشنل فائدا: Allows for strategic rotation/replacement of wear parts; provides predictive maintenance data on remaining liner life | ROI اثر: Optimizes liner changeout schedules during planned stops, maximizing utilization and parts investment
مرڪزي گريسنگ & PLC Control Hub | ٽيڪنيڪل بنياد: Automated singlepoint greasing for all bearings integrated into plant control system | آپريشنل فائدا: Simplifies routine maintenance; provides operators with realtime performance dashboards and fault diagnostics | ROI اثر: Reduces daily lubrication labor by 75% and shortens troubleshooting time significantly
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (Cone/Jaw Crusher Plants) | Primary Gyratory Crusher Solution | فائدو (% سڌارو) |
| : | : | : | : |
| دستيابي (اپٽائم)| 8590% due to bridging & more frequent liner changes| 9496% through nonchoking design & وڌيڪ لباس زندگي| +7% آپريشنل دستيابي |
| Tonnage per Installed HP| Lower ratio due to intermittent feeding & ڪمري جي جوڙجڪ| Higher ratio via continuous crushing action & optimal kinematics| +1520% توانائي جي ڪارڪردگي |
| Feed Top Size Capability| Limited by gape dimension; often requires prescreening| Accepts larger direct dump feed (up to 2m), simplifying loadout| Eliminates prescreening stage |
| قيمت في ٽون (لباس جا حصا)| Higher cost due to faster wear rates in abrasive limestone| Lower cost via massive liner design & strategic wear monitoring| 25% cost per ton crushed |
| Manpower for Operation| Often requires dedicated crusher operator/feeder watcher| Fully automated operation integrated with PLC/SCADA system| 1 FTE requirement |
5. ٽيڪنيڪل وضاحتون
ماڊل نامزدگي: GY5460 HD Limestone
گنجائش جي حد: 2,500 - 4,500 ٽين في ڪلاڪ (dependent on CSS and material work index)
فيڊ کولڻ: 1,370 ايم ايم
وڌ ۾ وڌ فيڊ سائيز: 2,000 ايم ايم (slabby limestone)
Nominal Discharge Setting Range: 150 - 250 ايم ايم
Installed Power: 450 ڪلواٽ (600 ايڇ پي) electric drive
ڪل وزن (صرف کولہو): ~275 tonnes
اهم مواد جي وضاحت: منٿ & Concaves – Manganese steel alloy with patented workhardening matrix; Main Shaft – Forged 34CrNiMo6; Base Frame – Fabricated heavyduty steel.
جسماني طول و عرض (LxWxH): ~6.5m x ~5m x ~4.5m (above foundation).
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 50 ° C تائين محيطي درجه حرارت لاء ٺهيل. Dust sealing rated for IP66.
6. درخواست جا منظر
Large Cement Plant Quarry Integration
چيلنج: A major cement producer faced inconsistent kiln feed quality due to fluctuating limestone size from their old jaw crusher circuit, causing inefficiencies in raw mill operation and higher specific energy consumption.
حل: Installation of a GY5460 HD Primary Gyratory Crusher as the new first reduction stage.
نتيجا: Achieved a consistent 200mm crusher product. This stabilized raw mill feed, resulting in a documented 8% reduction in specific energy consumption at the mill and a 12% increase in overall plant throughput due to eliminated upstream bottlenecks.
HighVolume Aggregate Quarry Expansion
چيلنج: An aggregate producer needed to expand annual output but was constrained by primary crushing capacity. Their existing system required frequent secondary breaking and suffered from daily bridging incidents.
حل: Commissioning of two parallel GY5460 HD crushers fed directly by 90ton haul trucks.
نتيجا：Bridging incidents were eliminated. The quarry increased average hourly throughput by over 40%, meeting expansion targets without adding a third shift. Secondary hammer operating costs were reduced by over 60%.
7. تجارتي خيالات
Equipment pricing is structured around configuration tiers:
بنيادي ٺاھ جوڙ جو درجو: Includes crusher, drive motor, lubrication system, and basic PLC controls.
Advanced Optimization Tier: Adds ASR System, integrated wear monitoring sensors, advanced predictive maintenance software suite.
Turnkey Installation Tier: Full engineering package including foundation design drawings, installation supervision,and commissioning services.
Optional features include dust suppression ring kits,tramp metal detection systems,and custom discharge conveyor flanges.
Service packages are offered as annual Performance Care Agreements covering planned inspections,predictive analytics review,and priority parts supply.Financing options include capital purchase,direct leasetoown models,and throughputbased agreements tailoredfor largescale projects.
8. FAQ
Q1：Is this primary gyratory crusher compatible with our existing downstream secondary cone crushersand screening plant?
A1：Yes.Field data shows its abilityto producea consistent,fineslimited product optimizes loadingand performanceof downstream stages.Engineering supportis providedto ensure interface compatibilitywith your existing conveyorsand chutework.
Q2：What isthe typical implementation timelinefrom orderto commissioning?
A2：Fora standard model,the lead timeis approximately89 months.Foundation constructioncan proceedin parallel upon receiptof detailed drawings.Onsite erectionand mechanical commissioningtypically require810 weekswith our supervision.
Q3：How doesthe automated setting regulationimpact final product specificationfor our aggregate products?
A3：The ASR systemmaintainsa tighter discharge setting tolerance.This directly translatesintoa more consistentfeedfor your secondary/tertiary stages,yielding superior controlover final aggregate gradationand increased yieldof inspecproduct.
Q4：What arethe critical spare partswe should planto stock?
A4：We recommendan initial spare parts kitincluding concave segments,چادر,bushing kits,and hydraulic cartridge filters.Ourbasedon your specific production forecastand local logisticsupport times.
Q5：Can this equipment handlethe occasional siliceous bandor chert nodulefoundin our limestone deposit?
A5：Yes.The heavyduty designincorporatesa hydroset systemthat allows the c rus herto pass uncrushablematerialby temporarily openingthe discharge setting,thereby providingprotection against tramp materialdamage.The robust main shaftassemblyis engineeredfor such shock loads.
Q6：What trainingis providedfor our maintenance crew?
A6：Comprehensive trainingis includedcovering operational procedures,scheduled maintenance tasks,troubleshooting usingthe PLC interface,and safety lockout protocols.This consistsof both classroominstructionand handson sessionsduring commissioning.
Q7：Are there financing options that align paymentwith achievingprojected production volumes?
A7：Yes.We offer structured financing solutionswhere repayment schedulescan be linkedto operational milestonesor throughput volumes.This helps manageinitial capital outlayand aligns ourobjectiveswith your production success
