1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Are escalating operational costs and unpredictable downtime eroding your primary crushing circuit’s profitability? Plant managers and engineering contractors consistently face critical challenges with their primary crushing assets:
Thời gian ngừng hoạt động đột xuất: Sự hao mòn sớm hoặc hư hỏng của các bộ phận quan trọng có thể làm dừng toàn bộ dây chuyền xử lý của bạn, gây thiệt hại hàng chục nghìn mỗi giờ trong sản xuất bị mất.
Chi phí bảo trì quá mức: Thay đổi lớp lót thường xuyên, lengthy maintenance windows, and high parts consumption directly impact your bottomline operating expenditure.
Thông lượng không nhất quán: Inefficient crushing chambers or suboptimal feed conditions lead to fluctuating tonnage, creating bottlenecks for downstream processes.
Tiêu thụ năng lượng cao: Older or poorly designed crushers operate with low mechanical efficiency, making power costs a significant and growing operational burden.
Rigidity to Feed Variation: Hard, abrasive ores or unexpected feed sizes can cause chokeups or accelerated wear, forcing production rate compromises.

Is your operation in need of a robust, highcapacity primary crusher engineered not just for peak performance, but for sustained reliability and lower total cost of ownership?

2. TỔNG QUAN SẢN PHẨM

A Gyratory Crusher is a stationary primary crushing machine central to largescale mining and aggregate operations. It utilizes a gyrating mantle within a concave housing to compress and fracture large feed material (typically above 1 meter in size) thành nhỏ hơn, manageable rock for secondary processing.

Quy trình hoạt động:
1. Lượng thức ăn ăn vào: Runofmine ore or large quarry rock is directed into the top of the crusher’s deep, rugged chamber via haul trucks or feeders.
2. Nghiền nén: The eccentrically driven mantle gyrates within the stationary concave liners, applying compressive force to reduce particle size through repeated cycles.
3. Phóng điện: Crushed material gravitates downward through the narrowing chamber until it reaches the desired size and exits through the discharge opening at the bottom.

Phạm vi ứng dụng & Hạn chế:
Phạm vi: Lý tưởng cho tải trọng cao (1,500+ TPH) primary crushing applications in hard rock mining (đồng, quặng sắt, vàng), large aggregate quarries, and major industrial mineral processing. Excels with abrasive and highstrength materials.
Hạn chế: Requires significant capital investment and substantial physical footprint. Not suitable for smallscale operations, mobile plants, or handling highly plastic or claybound materials that may cause packing.

3. TÍNH NĂNG CỐT LÕI

Hồ sơ lõm được cấp bằng sáng chế | Cơ sở kỹ thuật: Hình dạng buồng nghiền được tối ưu hóa | Lợi ích hoạt động: Delivers consistent product gradation and maximizes throughput across the liner life cycle | Tác động ROI: Reduces downstream circuit variability; dữ liệu trường cho thấy một 58% increase in average throughput versus conventional profiles.

Hệ thống điều khiển thông minh tích hợp | Cơ sở kỹ thuật: Realtime condition monitoring (áp lực , nhiệt độ, position) & automation interface | Lợi ích hoạt động: Your operators can optimize load distribution, predict maintenance needs, and prevent catastrophic damage | Tác động ROI: Prevents unplanned stops; industry case studies correlate this system with a 1520% reduction in major component failure rates.

HeavyDuty Main Shaft & Shell Design | Cơ sở kỹ thuật: Forged alloy steel shaft and robust spider assembly | Lợi ích hoạt động: Provides exceptional strength to withstand peak loads from uncrushable tramp material without structural damage | Tác động ROI: Eliminates costly shaft replacement events; extends major assembly service life by years.

Lube System with Dual Coolers | Cơ sở kỹ thuật: Highvolume circulation with redundant heat exchange capacity | Lợi ích hoạt động: Maintains optimal bearing temperature even in ambient conditions exceeding 45°C (113°F), ensuring viscosity stability | Tác động ROI: Directly protects the highestvalue bearings; documented to extend bearing life by up to 30% in hotclimate operations.

TopService Design Philosophy | Cơ sở kỹ thuật: All routine service points accessed from above via removable assembly | Lợi ích hoạt động: Cho phép an toàn hơn, faster liner changes and inspection without personnel working beneath suspended loads | Tác động ROI: Giảm thời gian dừng bảo trì theo kế hoạch lên tới 40% for liner replacement tasks.

Hệ thống truyền động hiệu suất cao | Cơ sở kỹ thuật: Direct gear drive or lowslip VSD coupling configured for your power grid | Lợi ích hoạt động: Transmits power with minimal parasitic loss; softstart capability reduces grid stress during startup | Tác động ROI: Energy consumption analysis indicates 37% lower specific energy use (kWh/tấn) compared to legacy directtie designs.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Điểm chuẩn tiêu chuẩn ngành | Giải pháp máy nghiền hồi chuyển của chúng tôi | Lợi thế được ghi lại |
| : | : | : | : |
| sẵn có (Operating Time) | 92 94% | > 96% | +24 điểm phần trăm |
| cuộc sống lót (Quặng mài mòn) | ~6 tháng | 7 8 Tháng| +1520% sự cải tiến |
| Tiêu thụ năng lượng cụ thể| Đường cơ sở (100%)| ~9395% of baseline| 57% sự giảm bớt |
| Thời gian trung bình giữa thất bại (Lớn lao)| ~24 Months| >36 Tháng| +50% increase |
| Throughput per Installed kW| Khác nhau tùy theo mô hình| Optimized chamber flow increases average yield by volume |

5. THÔNG SỐ KỸ THUẬT

Phạm vi công suất: Có thể cấu hình từ 2,000 đến hơn 10,000 tấn mỗi giờ (tph), dependent on model selection and feed material.
Motor Power Requirements: Typically from 450 kW lên đến 1,200+ kW. Engineered for compatibility with global voltages (ví dụ., 6.6 kV, 11 kV) and includes motor starter recommendations.
Thông số vật liệu: Key wear components manufactured from proprietary highstrength manganese steel alloys or composite materials. Main shaft is forged from vacuumdegassed alloy steel.
Kích thước vật lý & Cân nặng: Total installed weight ranges from approximately 250 tấn đến hơn 500 tấn. Comprehensive foundation loading diagrams are provided for engineering design.
Phạm vi hoạt động môi trường: Designed for ambient temperatures from 40°C to +50°C (40°F đến +122°F). Sealing systems are rated for highdust environments common in mining applications.

6. KỊCH BẢN ỨNG DỤNG

Mở rộng mỏ đồng quy mô lớn

Thử thách: A tierone copper operation needed to debottleneck its primary circuit to handle harder ore from a new pit zone. Their existing crusher suffered from low availability due to bearing overheating and frequent concave cracking.
Giải pháp: Implementation of a new heavyduty gyratory crusher featuring the dualcooler lube system and patented concave design suited for highly compressive ore.
Kết quả: Đạt được sản lượng bền vững hơn 6,500 tph with availability consistently above 96%. Specific energy consumption decreased by an average of ~6%, while liner life extended from an average of five months to seven months.

Nhà sản xuất tổng hợp đá granite lớn

Thử thách: A coastal quarry supplying megainfrastructure projects faced excessive maintenance time on its primary crusher due to complex liner change procedures causing unpredictable plant shutdowns.
Giải pháp: Installation of a topservice gyratory crusher designed specifically for abrasive granite feed.
Kết quả: Topservice access reduced planned liner change downtime by approximately onethird per event—translating to over four additional production days annually—and significantly improved worker safety during maintenance tasks.

7. CÂN NHẮC THƯƠNG MẠI

Our gyratory crushers are offered across several tiers based on size capacity:
Dòng nhiệm vụ tiêu chuẩn: For hightonnage aggregate applications (<12k Mpa compressive strength).
Dòng sản phẩm hạng nặng (Recommended for Mining): Engineered for continuous operation with hard/abrasive ores (>12k Mpa).
Optional features include advanced predictive analytics packages integrated into the control system custom wear protection packages based on specific ore abrasion indices remote diagnostic support capabilities

We offer comprehensive service agreements covering parts supply technical support scheduled inspections These can be structured as fixedcost annual plans providing budget certainty

Financing options including equipment leasing capital expenditure loans project financing structures are available through our network partners facilitating cash flow management

Câu hỏi thường gặp

1. Q How do I determine if this gyratory crusher is compatible with my existing plant footprint?
A We provide detailed dimensional layout drawings including all service clearances Our engineering team can conduct a site integration review using your existing plans

2 Q What is the expected impact on my overall plant throughput?
A Based on historical data our optimized chamber designs typically deliver more consistent product sizing which often increases downstream milling circuit efficiency contributing directly higher overall plant yield

3 Q What are typical lead times?
A Lead times vary based on model complexity current order book For standard heavyduty models typical manufacturing delivery ranges between months We provide firm schedules upon project commitment

4 Q How does pricing compare total cost ownership versus other options?
A While initial capital investment is significant field performance reports confirm that superior availability longer component life lower energy consumption result lower operating cost per ton crushed which defines true value over year lifespan

5 Q What level technical support provided during commissioning?
A Commissioning supervised our experienced field engineers includes operator training performance baselining final system tuning ensure design specifications met We remain available remote support thereafter