H1: HighCapacity, LowCostPerTon Gold Ore Crushing Solutions

1. PAINPOINT DRIVEN OPENING

Processing gold ore presents a distinct set of crushing challenges that directly erode profitability. Are you facing these costly operational realities?

High Abrasion Costs: The quartz and hard rock matrices common in gold ores rapidly wear crusher components, leading to frequent liner changes, excessive spare parts inventory, and unplanned maintenance stops.
Throughput Bottlenecks: Inconsistent feed size or capacity limitations in primary crushing stages constrain the entire milling circuit, leaving valuable tonnage—and revenue—unprocessed.
Energy Intensity: Traditional crushing stages consume significant power. Inefficient comminution directly increases your highest variable cost: energy per processed ton.
Downtime for Maintenance: Every hour a primary or secondary crusher is down for liner replacement or adjustment halts the entire processing plant, costing thousands in lost production.

The central question for plant managers is this: How can you achieve the required particle reduction for optimal gold recovery while controlling wear costs, maximizing throughput uptime, and minimizing specific energy consumption? The answer begins with selecting the right sustainable gold ore crushing equipment.

2. PRODUCT OVERVIEW

This product line focuses on Primary Gyratory Crushers and Secondary Cone Crushers engineered specifically for the demands of hard rock gold ore processing. These machines form the critical first stages of size reduction, setting the foundation for downstream grinding and recovery efficiency.

Operational Workflow:
1. RunofMine (ROM) ore is fed into the primary gyratory crusher’s receiving hopper.
2. The gyrating mantle within the fixed concave crushes large rocks (often up to 1.5m) against high pressure, reducing them to a manageable size (typically 250mm).
3. Crushed material is conveyed to a secondary cone crusher for further reduction to a finer product (typically 50mm), optimized for feed to SAG or ball mills.
4. The precisely controlled discharge setting ensures a consistent product size, improving overall circuit stability and recovery rates.

Application Scope & Limitations:
Scope: Ideal for medium to hightonnage hard rock gold operations (2,000+ TPD). Effective on lode ore, vein material, and oxidized deposits with high compressive strength.
Limitations: Not suitable for clayrich or highly weathered alluvial deposits where alternative crushing methods may be preferred. Requires stable foundational support and controlled feed systems for optimal operation.

3. CORE FEATURES

Patented Chamber Geometry | Technical Basis: Optimized nip angle and crushing stroke | Operational Benefit: Produces a more cubical product with fewer fines at the primary stage, reducing overgrinding in downstream mills | ROI Impact: Field data shows up to an 8% reduction in specific energy consumption in the grinding circuit.

Automated Wear Compensation | Technical Basis: Hydraulic adjustment system with ASRi™ (Automatic Setting Regulation) technology | Operational Benefit: Maintains consistent crusher discharge setting as liners wear, ensuring stable product gradation without manual intervention | ROI Impact: Delivers up to 15% more consistent throughput and protects downstream processes from feed variability.

HeavyDuty Mainframe & Forged Shaft | Technical Basis: Singlepiece cast steel base and highintegrity alloy forging | Operational Benefit: Provides exceptional durability under shock loads from uncrushable material, minimizing risk of catastrophic frame failure | ROI Impact: Extends operational life by years and reduces total cost of ownership through structural reliability.

Liner Life Enhancement System | Technical Basis: Computeroptimized liner profiles and zincfree backing resin application | Operational Benefit: Ensures even wear distribution and secure liner seating, maximizing manganese utilization and simplifying changeouts | ROI Impact: Industry testing demonstrates a 2030% improvement in liner life compared to nonoptimized designs.

Integrated Dust Sealing & Containment | Technical Basis: Positivepressure labyrinth seal with dedicated air purge system | Operational Benefit: Effectively prevents dust ingress into the internal lubrication system, protecting critical bearings and gears from abrasive contamination | ROI Impact: Extends bearing service life by up to 50%, preventing costly unscheduled repairs.

Centralized Greasing & Lubrication | Technical Basis: Automated singlepoint greasing system for all major wearing points with realtime monitoring | Operational Benefit: Eliminates manual greasing requirements at multiple hardtoaccess points, enhancing safety and ensuring optimal lubrication intervals are met consistently| ROI Impact: Reduces labor costs for routine maintenance and decreases risk of premature failure due to underlubrication.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gold Ore Crushing Solution Documented Advantage |
| : | : | : |
| Availability (Uptime) | ~92% (including planned maintenance) |>96% through extended wear life & quickchange designs |
| Specific Energy Consumption (kWh/t) Varies by ore competency.| Baseline set at 100% |>92% due to efficient chamber design & optimal speed |
| Manganese Liner Cost/Ton Processed| Baseline set at 100% |>75% via optimized profiles & material technology |
| Mean Time Between Failure (MTBF) Major Components| ~8,000 operating hours |>12,000 operating hours via superior metallurgy & sealing |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 1,500 to over 10,000 metric tons per hour (TPH), depending on model selection and circuit configuration.
Power Requirements: Primary crushers from 300 kW to over 800 kW; Secondary crushers from 150 kW to 450 kW. All motors are compatible with standard highvoltage mine power distribution systems.
Material Specifications: Highstrength alloy steel mainframes; Austenitic manganese steel crushing liners; Forged alloy steel main shafts; Sealed spherical roller bearings on all major loads.
Physical Dimensions (Example Model): Primary Gyratory Approx. Height: 6m; Width: 5m; Weight: ~250 tonnes. Secondary Cone Approx. Height: 3m; Width: 3m; Weight:~45 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 40°C to +50°C. Dust protection rating ensures reliable operation in harsh mining environments.

6. APPLICATION SCENARIOS

Hard Rock Underground Mine Expansion Challenge:

A North American gold mine expanding underground operations needed a primary crushing solution with a smaller footprint than their existing jaw crusher but equivalent capacity to handle increased tonnage of highgrade quartz ore.

Solution:

Implementation of a midrange gyratory crusher designed specifically for underground installation constraints as their primary sustainable gold ore crushing equipment.

Results:

Achieved target throughput of 2,800 TPH within footprint constraints while reducing primary crush product P80 by 15%. This finer feed contributed directly measured results including an increase in overall plant throughput by approximately9%.

Refractory Ore Processing Plant Upgrade Challenge:

An Australian operation processing refractory sulfide gold ore faced excessive wear costs in secondary crushing due to extreme abrasiveness causing monthly liner changes that halted production

Solution:

Retrofitting of two secondary cone crushers equipped with automated wear compensation specialized ultrawearresistant liner alloys

Results:

Liner life extended from an average of28 days42 days representing25 improvement Reduced annual planned downtime hours by180 hours resulting additional processing12k tons highvalue refractory material annually

7 COMMERCIAL CONSIDERATIONS

Our sustainable gold ore crushing equipment is offered under flexible commercial terms designed for capital project planning:

Pricing Tiers: Equipment pricing is structured based on capacity size range offering entrylevel intermediate models fullscale production units
Optional Features: Key upgrades include advanced predictive monitoring sensors remote access diagnostics packages automated lubrication systems specific liner profile options tailored your ore type
Service Packages: Choose from basic commissioning support comprehensive multiyear service agreements covering scheduled maintenance parts supply technical support
Financing Options: We partner with leading industrial finance providers offer leasetoown structures longterm operating leases traditional purchase arrangements accommodate various budget cycles balance sheet requirements

8 FAQ

Q1 Are your cone crushers compatible with existing jaw crusher feed systems?
A1 Yes most models can be integrated into existing circuits Engineering reviews are conducted ensure proper feed box design conveyor transfer points alignment

Q2 What is typical installation commissioning timeline?
A2 For greenfield projects typical timeline ranges16 weeks site preparation mechanical erection electrical connection commissioning Brownfield replacements can often completed within68 weeks detailed planning

Q3 How does automated setting regulation impact my operators workload?
A3 It significantly reduces need manual adjustments allows operators focus monitoring overall plant performance rather than constant crusher tweaking This leads more stable operation reduced human error

Q4 What spare parts inventory recommended ensure uptime?
A4 We provide critical spares kit recommendation based your specific operation typically includes initial set liners key hydraulic components sensors This minimizes lead time risk initial years operation

Q5 Do you offer performance guarantees?
A5 Yes we provide guaranteed capacity throughput figures based agreed feed material characteristics as well guaranteed maximum specific wear rates manganese liners under defined conditions

Q6 Can equipment handle tramp steel events?
A6 All primary units equipped with hydraulic overload protection system that automatically releases clearing chamber uncrushable material minimizing risk damage allowing rapid resumption production