Horizontal gyratory crusher for mining and quarrying

The DLHGC Horizontal Gyratory Crusher combines the performance advantages of gyratory and jaw crushers, utilizing layer-crushing technology at its core. It is specifically designed for ultra-hard ores and rocks—such as iron ore, copper ore, granite, basalt, and quartzite—with a compressive strength exceeding 320 MPa. With a lower feed height than traditional gyratory crushers, it reduces civil engineering foundation costs by 60–70%, making it particularly suitable for underground mine layouts. With a maximum feed size of ≤1200 mm and a capacity of 800–3500 tons per hour, this unit features crushing rollers that rotate in opposite directions to evenly wear the liners, dual hydraulic overload protection, and intelligent one-button operation, making it a heavy-duty core piece of equipment for primary coarse crushing in large-scale mines.

Laminated Bed Crushing: Multi-stage compression within an extra-long, constant-width crushing chamber ensures excellent particle size consistency, reducing re-crushing and unnecessary energy consumption

Low Feed Height: Reduces civil engineering foundation costs by 60–70% compared to traditional gyratory crushers, significantly minimizing excavation requirements in underground mine chambers

Feed Size ≤1200 mm: Capable of directly processing blasted rock with an oversized feed opening, simplifying production processes

Reversing Crushing Rolls for Even Wear: Ensures uniform stress distribution on liners, eliminates localized wear, and extends service life by approximately 100%

Dual hydraulic overload protection: Pressure and displacement sensors work in tandem; automatic protection activates upon overload or foreign object intrusion, with rapid recovery without shutdown

Intelligent one-button control: Parameterized settings, real-time digital display, and hydraulic interlocks ensure simple operation and stable performance

 

Large-scale metal mines: Primary coarse crushing in open-pit or underground iron, copper, and gold mines, replacing traditional gyratory crushers with high feed heights

Ultra-hard rock quarries: Primary crushing in high-hardness quarries such as granite and diabase, resolving capacity bottlenecks associated with standard jaw crushers

Underground mining crushing systems: Construction of high-capacity primary crushing stations with low infrastructure costs in space-constrained environments

Large-scale aggregate production lines: Paired with the DLHPT multi-cylinder cone crusher for secondary and tertiary crushing to form a high-capacity complete production line

Customized process for primary coarse crushing in large-scale hard rock mines:

Large rock blocks (≤1200 mm) from blasting are directly fed into the DLHGC feed inlet. The material undergoes multi-stage interlayer crushing within an extra-long, constant-width crushing chamber, gradually reducing in size. A fixed discharge opening ensures stable product size (typically ≤300 mm). The crushing rollers periodically reverse to ensure even wear of the liners, reducing the frequency of shutdowns for liner replacement. The coarse-crushed material is conveyed via a belt to the second-stage DLHPT multi-cylinder cone crusher for medium and fine crushing. Combined with a closed-circuit system using a vibrating screen, this process produces qualified aggregate. An intelligent system monitors the entire process, while dual hydraulic overload protection addresses foreign object contamination, ensuring 24/7 uninterrupted production.

 

Solution Design: Tailor-made machine models and civil engineering foundation plans based on rock type, hardness, production capacity targets, and underground/open-pit operating conditions

Equipment Manufacturing: Crushing roller assemblies, extra-long chamber liner plates, hydraulic protection systems, and intelligent control systems are all manufactured in-house; heavy-duty castings undergo strict quality inspection

Installation and Commissioning: Engineers travel to the site to complete hoisting and positioning, hydraulic interlock debugging, control parameter calibration, and trial production

Operation and Maintenance Management: Wear warning for crushing rolls and liners, regular inspections and maintenance, spare parts stockpiling, and rapid response to failures, ensuring the continuous and stable operation of large-scale mining crushing lines

Project Location: Primary Crushing Project at an Iron Ore Mine in Minas Gerais, Brazil

With an ore compressive strength of approximately 340 MPa and a daily processing capacity exceeding 50,000 tons, the underground crushing chamber faced space constraints. One DLHGC horizontal gyratory crusher was selected, with a maximum feed size of 1,100 mm. The operating output remains stable at 2,200 tons per hour, and the final product size of ≤280 mm meets the feed requirements for the subsequent cone crusher. The excavation volume for the underground chamber was reduced by approximately 55%, civil engineering costs were cut by about 65%, and the construction period was shortened by 4 months. The liner replacement cycle was extended from 3 months to 7 months, reducing annual consumable costs by 45%. The hydraulic overload protection system automatically activated three times within two years, preventing equipment damage. Customer feedback: “The low feed height really helped us save a significant amount on underground engineering costs, and we haven’t had any major issues in two years of operation.”

Horizontal Gyratory Crusher FAQ