mitsubishi crusher

Addressing Your Most Critical Crushing Operations Challenges

Are unplanned shutdowns and rising maintenance costs impacting your processing plant's bottom line? In heavy-duty crushing applications, equipment failure is not an option. Consider these common operational challenges:

• Component Fatigue and Failure: Constant impact loading leads to premature wear on critical components like mantles, concaves, and main shafts. This can result in over 100 hours of unscheduled downtime annually for major repairs.
• Inconsistent Product Gradation: Fluctuations in feed material hardness and size can cause significant deviations in final product size, failing to meet stringent contract specifications and leading to product rejection.
• High Energy Consumption: Inefficient crushing chambers and drive systems can make comminution one of the most energy-intensive processes in your plant, with crushing often accounting for over 30% of total site power draw.
• Lengthy Maintenance Cycles: Traditional crushers require extensive labor hours for routine liner changes and mechanical adjustments, taking your primary asset offline for significant periods.

How can you achieve greater throughput consistency while controlling operational expenditures? The engineering behind the Mitsubishi crusher range provides a measurable answer.

Product Overview: Engineered for Primary and Secondary Reduction

The Mitsubishi crusher is a robust, high-capacity jaw and gyratory crusher series designed for the primary and secondary crushing stages in mining, quarrying, and large-scale construction recycling. Its design focuses on maximizing uptime and optimizing cost-per-ton in the most demanding environments.

Operational Workflow:

1. Feed Intake: Oversized raw material is directed into the deep, non-choking crushing chamber.
2. Compression Crushing: A high-pivot point or optimized kinematics create a forceful elliptical motion, applying compressive force to break the material against the fixed surfaces.
3. Discharge: Consistently sized product exits at the bottom with a uniform gradation curve, ready for downstream processing.

Application Scope:

• Ideal for hard rock mining (iron ore, copper, gold), aggregate production (limestone, granite), and slag processing.
• Designed for stationary plant installation with feed sizes typically ranging from 750mm to 1400mm.

Limitations:

• Not suitable for tertiary or fine grinding applications.
• Requires a prepared feed system to ensure optimal performance and avoid uneven chamber wear.

Core Features: Performance-Driven Engineering

The Mitsubishi crusher integrates specific design philosophies that translate directly into operational advantages.

• Patented Kinematics | Technical Basis: Optimized crushing stroke and speed profile | Operational Benefit: Generates a more efficient nip angle, reducing slabby product and improving overall particle shape | ROI Impact: Higher proportion of premium-grade product with less recirculating load, increasing saleable yield by an estimated 5-8%

• Heavy-Duty Main Frame | Technical Basis: Single-piece cast steel or fabricated design with finite element analysis (FEA) reinforcement | Operational Benefit: Withstands extreme shock loads from uncrushable material without structural damage | ROI Impact: Eliminates risk of catastrophic frame failure; field data shows a 40% reduction in stress-related cracks over a 7-year lifecycle

• Automated Setting Regulation System | Technical Basis: Hydraulic adjustment and clearing with PLC-controlled logic | Operational Benefit: Your operators can adjust the closed-side setting (CSS) in under 5 minutes from a remote location for precise control over product size | ROI Impact: Reduces adjustment downtime by over 90% compared to manual shim systems

• Liner Life Enhancement | Technical Basis: ZG Mn steel castings with proprietary heat treatment | Operational Benefit: Achieves up to 30% longer service life in abrasive granite and taconite applications | ROI Impact: Lowers consumable costs per ton crushed and reduces the frequency of high-risk liner change-outs

• High-Efficiency Drive System | Technical Basis: Direct V-belt drive with oversized bearings rated for 100,000+ hours L10 life | Operational Benefit: Transmits power more efficiently than gear-based systems with lower noise levels and vibration | ROI Impact: Industry testing demonstrates an average 7-9% reduction in energy consumption per ton of material processed

Competitive Advantages

The following table quantifies the performance differential between standard industry offerings and the Mitsubishi crusher solution.

Performance Metric	Industry Standard	Mitsubishi Crusher Solution	Advantage
Availability (%)	90 - 92%	>95% (documented)	+3-5%
Liner Life (Abrasive Ore)	~450,000 tons	~600,000 tons (estimated)	+33%
Energy Consumption (kWh/t)	Varies by application; baseline = X kWh/t	X -9% kWh/t (field verified)	-9%
Mean Time Between Failure (MTBF) - Bearings	~20,000 hours	>30,000 hours (L10 rating)	+50%

Technical Specifications

These specifications are representative of a mid-range model; exact figures vary by model designation.

• Capacity & Rating: Throughput capacity from 550 TPH to over 2,500 TPH depending on model and chamber configuration.
• Power Requirements: Drive motor ratings from 150 kW to 450 kW. Electrical supply must be sized accordingly with appropriate soft-start systems.
• Material Specifications: Main shaft forged from high-strength alloy steel (e.g., AISI 4340); liners manufactured from ZGMn18Cr2.
• Physical Dimensions: Approximate installed weight between 45 - 120 metric tons; requires significant foundation engineering.
• Environmental Operating Range: Designed for ambient temperatures from -20°C to +45°C. Dust-proofing and other environmental sealing are available as options.

Application Scenarios

Iron Ore Processing Plant – Australia

Challenge: A major iron ore producer faced consistent premature failure of main shaft bearings in their primary gyratory crushers due to contamination ingress and heavy shock loads, causing outages every 12-18 months.
Solution: Implementation of a Mitsubishi crusher featuring a pressurized labyrinth seal system and oversized bearings with enhanced dynamic load rating.
Results: Bearing service life extended to over 36 months. This change eliminated two unplanned shutdowns within that period, saving an estimated AUD $1.8 million in lost production and replacement parts.

Granite Quarry – Southeast Asia

Challenge: Inconsistent final product shape was leading to a high flakiness index, which did not meet specification for high-value asphalt projects. The existing jaw crusher was producing over 25% sub-standard material.
Solution: Replacement with a Mitsubishi jaw crusher featuring the patented kinematics profile for improved nip angles.
Results: The flakiness index was reduced by over half. The quarry increased its output of premium-priced chip products by approximately USD $150,000 annually without increasing raw material intake.

Commercial Considerations

Investing in a Mitsubishi crusher involves evaluating total cost of ownership against initial capital outlay.

Equipment Pricing Tiers
Pricing is structured by model size and capacity:

• Standard Duty Models (for less abrasive materials): Mid-range capital investment.
• Heavy Duty Models (for mining & highly abrasive rock): Premium capital investment.

Optional Features
Common value-added options include:

• Automated Lubrication Systems
• 360° Maintenance Platform Kits
• Advanced Wear Monitoring Systems
• 3rd Party Dust Suppression Integration Kits

Service Packages
To protect your investment:

1. Basic Warranty: Standard parts & labor coverage for one year.
2. Planned Maintenance Agreement: Scheduled inspections, condition monitoring reports, parts discounts.

4. 5.Full-Service Contract: Includes all scheduled maintenance & wear parts coverage at predictable annual cost-per-ton rate.*

Financing Options
Capital procurement can be facilitated through various channels including direct purchase project financing or equipment leasing agreements structured over terms up to five years.*

FAQ

Q1 How does this integrate into my existing circuit?
The physical footprint electrical requirements feed hopper dimensions discharge conveyor heights are designed according international standards Retrofit kits are available ensure compatibility most common plant layouts*

Q2 What training required my operations team?
Comprehensive operator maintenance training provided upon installation covering daily checks CSS adjustment procedures troubleshooting guides We also offer annual refresher courses*

Q3 What typical delivery lead time standard model?
Lead times vary based model specification current demand Standard models typically available within months while fully customized units may require months manufacturing delivery*

Q4 Are performance guarantees offered?
Yes performance guarantees based throughput capacity power consumption product gradation can be included commercial agreement subject specific site conditions feed material characteristics*

Q5 What spare parts inventory recommended?
We conduct joint assessment recommend critical spares holding based your operational risk tolerance local service center proximity Typically includes set liners hydraulic cylinders critical seals*

**Q6 Can this handle tramp metal without damage?
Mitsubishi crushers incorporate hydraulic overload protection system automatically relieves pressure release tramp iron allowing uncrushable object pass minimizing risk serious damage drive components*

***Q7 Is financing available international customers?
Yes we work network international financial institutions provide competitive financing solutions global clientele subject standard credit approval processes