1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your aggregate production margins? For plant managers and engineering contractors, the core crushing circuit is often the source of critical bottlenecks. Common challenges include:
Unscheduled Downtime: Frequent liner changes and unexpected mechanical failures halt your entire processing line, costing thousands per hour in lost production.
High Wear Part Consumption: Aggressive or abrasive feed material leads to premature wear on mantles, concaves, and jaw plates, creating volatile and recurring operational expenses.
Inconsistent Product Gradation: Fluctuations in feed size or hardness result in offspec product, leading to recrushing cycles, wasted energy, and dissatisfied customers.
Rising Energy Costs: Inefficient crushing chambers and outdated drive systems draw excessive power without maximizing throughput per kilowatthour.
Limited Flexibility: Fixed configurations cannot adapt to changing feed materials or market demands for different aggregate sizes without significant manual adjustment and time.

Is your primary crushing station a cost center or a controlled, efficient asset? The solution lies not just in a machine, but in a engineered system designed for total cost of ownership.

2. PRODUCT OVERVIEW: HYDRAULIC CONE CRUSHER

The modern hydraulic cone crusher is a secondary/tertiary reduction machine engineered for highvolume production of consistent, cubical aggregate. Its operational workflow is centered on continuous compression crushing:
1. Feed Introduction: Sized feed from a primary jaw crusher is directed into the top of the crushing chamber.
2. Compressive Reduction: The rotating mantle gyrates within a stationary concave liner, repeatedly compressing rock against rock until it fractures to size.
3. Dynamic Adjustment: A hydraulic system allows for realtime adjustment of the crusher’s closedside setting (CSS) during operation to maintain product spec.
4. Discharge & Clearing: Crushed material falls by gravity to the discharge point. An automatic hydraulic clearing system rapidly releases the chamber to pass tramp metal or uncrushable material, minimizing stall risk.

Application Scope: Ideal for hard and abrasive materials (granite, basalt, quartzite) in stationary aggregate plants and large mining operations. Best suited for feed sizes typically under 250mm.
Key Limitation: Not designed for primary crushing of runofquarry material or handling significant plastic/clay content without prescreening.

3. CORE FEATURES

Hydroset Control System | Technical Basis: Hydraulic pressure regulation of the main shaft position | Operational Benefit: Allows operators to adjust crusher CSS remotely in under one minute for product gradation changes or wear compensation without stopping the crusher. | ROI Impact: Reduces nonproductive adjustment time by up to 80% compared to manual shim systems, increasing plant availability.

Patented Crushing Chamber Design | Technical Basis: Computeroptimized geometry for interparticle rockonrock crushing | Operational Benefit: Promotes a denser particle bed where rocks crush each other, not just the liners; produces superior cubicity while distributing wear more evenly. | ROI Impact: Can increase liner life by 1530% depending on material abrasiveness, directly lowering costperton for wear parts.

Automated Overload Protection | Technical Basis: Pressure sensors monitoring main shaft hydraulic pressure | Operational Benefit: Instantly detects an overload condition (e.g., tramp metal) and triggers the clearing cycle automatically, protecting the mechanical components from catastrophic damage. | ROI Impact: Prevents expensive repairs to head, shaft, and eccentric assembly; field data shows a reduction in major failure events by over 90%.

DualActing Hydraulic Cylinders | Technical Basis: Hydraulic cylinders that provide both upward force for setting adjustment and downward force for clearing | Operational Benefit: Delivers faster, more powerful clearing strokes compared to springrelease systems, ensuring reliable recovery from cavity packing events. | ROI Impact: Minimizes downtime associated with digging out a stalled crusher—a process that can take hours.

Centralized Greasing System | Technical Basis: Automated singlepoint lubricant delivery to key bearings and gears | Operational Benefit: Ensures correct lubrication intervals and volumes without manual intervention at multiple grease points located in hazardous areas. | ROI Impact: Extends bearing service life by preventing under/overgreasing; reduces required maintenance labor hours per week.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Mechanical Spring Cone) | Hydraulic Cone Crusher Solution | Advantage |
| : | : | : | : |
| CSS Adjustment Time (During Operation) | 24 Hours (Manual Shim) | 95% Faster |
| Tramp Iron Clearing & Recovery Time| 3060 Minutes (Manual) / Variable Spring Return| 90% Faster |
| Liner Life Consistency (Abrasive Granite)| High Variability (±20%)| More Predictable Wear Profile (±5%)| Improved Planning & Inventory Control|
| Energy Efficiency (kWh/Ton)| Baseline| Up to 10% Improvement via Optimized Chamber| Direct Power Cost Savings|
| Product Shape (% Cubical)| Varies with Wear & Feed| Consistent >85% Cubicity Maintained| Higher Product Value & Less Recirculation|

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: 100 – 900 metric tons per hour (dependent on chamber selection & CSS).
Motor Power Requirement: 150 kW – 600 kW (200 HP – 800 HP), supplied at 50/60 Hz as required.
Maximum Feed Size: Accepts feed up to 85% of inlet opening dimension; typical max feed ≤250mm.
Material Specifications: Highstrength cast steel main frame; manganese steel wearing liners; forged alloy steel main shaft.
Physical Dimensions (Typical MidRange Model): Approx. Length: 4m x Width: 3m x Height: 3m (excluding motor & walkways).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with appropriate lubricants. Dust seals rated for standard quarry conditions.

6. APPLICATION SCENARIOS

Granite Quarry Expansion Project

Challenge: A large granite quarry needed to increase secondary crushing capacity by 40% but had limited physical footprint for expansion and needed stricter control over chip product gradation for asphalt mixes.
Solution: Implementation of two highcapacity hydraulic cone crushers with automated setting regulation replaced three older mechanical units.
Results: Achieved a 45% throughput increase within the existing footprint while reducing energy consumption per ton by 8%. Product gradation consistency improved such that recrushing of offspec material fell by over 70%.

Portable Contract Crushing Operation

Challenge: A contracting firm faced excessive mobilization time and high liner costs when moving between sites with varying rock hardness (limestone to hard gravel).
Solution: Deployment of a tracked plant featuring a hydraulic cone crusher with quickchange liner kits and remote CSS control.
Results: Sitetosite setup time reduced by one full working day due to rapid calibration. The ability to finetune CSS daily optimized liner life across different materials, extending average campaigns by an estimated 25%.

7. COMMERCIAL CONSIDERATIONS

Hydraulic cone crushers are offered across several investment tiers:
Standard Duty Tier: For consistent, moderately abrasive materials like limestone; focuses on core reliability with essential automation features.
Heavy Duty / Premium Tier: For highly abrasive materials (trap rock, granite); includes enhanced wear packages, advanced monitoring sensors as standard.
Modular/SkidMounted Tier: Preassembled units with integrated lubrication and hydraulic systems reduce installation time and cost by up to onethird.

Optional features include advanced telemetry packages for remote performance monitoring automated wear compensation software based on amp draw trends

Service packages range from basic preventive maintenance plans up through comprehensive guaranteed uptime contracts which include planned parts replacement

Financing options are available including equipment leasing capital loans through partner institutions

FAQ

1.Q What level of operator training is required versus our older mechanical spring cone crushers?
A Operators require specific training on the hydraulic control system interface which typically takes two days However overall operation is simplified as many critical functions like setting adjustment are automated reducing reliance on manual skill

2.Q Can this technology be integrated with our existing primary jaw crusher screening plant?
A Yes these units are engineered as modular components Standard discharge conveyor dimensions electrical interfaces allow integration into most existing circuits Plant layout review is recommended during quotation

3.Q How does automation impact longterm maintenance costs?
A While initial component complexity may be higher predictive diagnostics prevent catastrophic failures Scheduled maintenance becomes more predictable Industry data indicates total maintenance costs over years can be lower due avoided major breakdowns

4.Q What financing structures are commonly used?
A Common structures include capital equipment loans operating leases master rental agreements Purchase options often exist at lease end We can provide net present cost analysis comparing models

5.Q Are there application limits where this technology is not advised?
A This technology is not optimal as primary unit processing unscreened runofquarry material with high fines clay content which can cause packing It excels as secondary tertiary unit receiving presized feed