When our client, a key player in the mining industry, faced excessive downtime and operational inefficiencies with their primary gyratory crusher, they turned to EARTHRES for a solution. Their existing primary gyratory crusher was causing unforeseen challenges that threatened to disrupt their operations. EARTHRES conducted a thorough analysis, specified a new primary Gyratory crusher, and provided comprehensive support. The result was significantly reduced downtime, increased efficiency, and a more stable operation.
The implementation of the new crusher, along with comprehensive support from EARTHRES, brought significant benefits to the client:
Reduced Downtime: The new crusher’s design and installation minimized unscheduled downtime, allowing for continuous operations.
Enhanced Efficiency: Replacing an 800 hp crusher with a 500 hp crusher not only increased efficiency but also contributed to operational stability.
Improved Safety and Maintenance with 360° access to all levels of the Crusher: The original design had no provision for maintenance access below the crusher except through a manhole into a confined space.
Enhancing access to the crusher through the use of a removable rolling platform and new fixed platforms facilitated efficient and safer maintenance while reducing repair times and costs.
Increased Production Rate: The average production rate increased from 1200 TPH to 2000 TPH, demonstrating a marked improvement in throughput.
Operational Cost Savings: Operational improvements eliminated the need for a 2nd shift, significantly reducing annual operating costs.
Return on Investment: The project achieved ROI in only 2 years, which is half of the normal ROI for a project of this nature.
Operational Stability: The upgraded drive arrangement and structural reinforcements minimized failures and the need for outside contractor intervention.
EARTHRES’ Mining Engineering Consulting services provided thorough analysis, strategic planning, and expert execution to overcome significant operational challenges. By implementing the process solution and providing ongoing support, they enabled their client to achieve greater efficiency and stability in their operations.
EARTHRES continues to collaborate with this client to find innovative solutions to further optimize their processes and achieve new levels of operational excellence.
Click the links to learn more about our Mining Process Plant Design and our Mining Operations & Maintenance Support Services.