1. PYNPUNT GEDREWE OPENING

Die bestuur van slak is 'n aanhoudende bottelnek met tasbare koste. Staan jy hierdie operasionele uitdagings in die gesig?
Lae deurset & Hoë stilstandtyd: Inefficient primary crushing creates a backlog, halting downstream processing and delaying material recovery. Every hour of unplanned downtime represents significant lost revenue.
Excessive Abrasion & Onderhoudskoste: The highly abrasive nature of slag rapidly wears down standard crusher components, leading to frequent part replacements, hoë onderdele voorraad, and costly labor for unscheduled maintenance.
Unreliable Size Reduction: Inconsistent feed size and composition from slag heaps result in poor fragmentation. This causes chokeups, reduces crusher efficiency, and produces an uneven end product that hampers subsequent separation or sale.
Hoë bedryfskoste: The combined effect of energyinefficient crushing, constant maintenance, and process delays erodes your profit margin on recovered metal and aggregate.

Is your current slag processing system a source of recurring cost and disruption? A purposeengineered slag crusher plant directly addresses these pain points by transforming waste handling into a reliable, profitable recovery operation.

2. PRODUK OORSIG

A modern slag crusher plant is a stationary or semimobile integrated processing system designed specifically for the size reduction and liberation of metallic fractions from steel, koper, or ferroalloy slag. It transforms raw slag feed into a consistently sized aggregate for sale or further processing.

Operasionele werkvloei:
1. Primêre verplettering: Groot slak stukke (up to 1m³) are reduced to manageable sizes (tipies <200mm) met behulp van 'n robuuste kakebeenbreker of impakbreker.
2. Sekondêre verplettering & Bevryding: Material undergoes further reduction in a cone or impact crusher to liberate embedded metal beads from the mineral matrix.
3. Sifting & Skeiding: Crushed material is screened into specified aggregate fractions (bv., 05mm, 520mm). Liberated metal is recovered via magnetic separators.
4. Materiaalhantering: Conveyors transport both the cleaned aggregate and recovered metal to designated stockpiles for dispatch.

Toepassingsomvang: Ideaal vir geïntegreerde staalaanlegte, minimeulens, kopersmelters, slakverwerkingswerwe, and recycling contractors handling blast furnace (BF) slak, basiese suurstof oond (BOF) slak, elektriese boogoond (EAF) slak, en nie-ysterhoudende slakke.

Beperkings: Nie ontwerp vir primêre ertsverwerking of uiters harde rots nie (>250 Mpa). Feed material must be free of explosive contaminants and oversized tramp metal beyond the system’s designed protection limits.

3. KERNKENMERKE

HeavyDuty Primêre Breker | Tegniese basis: Hoë mangaanstaal kake met geoptimaliseerde kneephoek | Bedryfsvoordeel: Handvatsels groot, onreëlmatige blaaie sonder oorbrugging; withstands extreme shock loads | ROI impak: Reduces primary breakdown time by up to 40%, lowering labor costs per ton processed.

Geïntegreerde metaalskeiding | Tegniese basis: Overband magnetic separator positioned postcrushing | Bedryfsvoordeel: Automatically extracts ferrous scrap from the crushed stream for direct sale | ROI impak: Creates a secondary revenue stream; protects downstream equipment from metal damage.

Skuurweerstandige voeringstelsels | Tegniese basis: Wearresistant steel plates in feed hoppers, val, and impact zones | Bedryfsvoordeel: Extends service intervals for highwear components by 23x | ROI impak: Lowers annual spare parts expenditure and reduces maintenance downtime.

Gesentraliseerde PLC-beheerstelsel | Tegniese basis: Automated process control with motor monitoring and fault diagnostics | Bedryfsvoordeel: Enables singleoperator oversight; provides clear alerts for jams or overloads | ROI impak: Optimaliseer kragverbruik; prevents catastrophic failures through early intervention.

Modulêre SkidMounted Ontwerp | Tegniese basis: Preassembled modules on heavyduty frames | Bedryfsvoordeel: Reduces onsite civil work and installation time by approximately 60% | ROI impak: Faster commissioning leads to quicker return on investment; allows for future plant relocation.

Stofonderdrukkingstelsel | Tegniese basis: Strategically placed spray nozzles at transfer points | Bedryfsvoordeel: Maintains compliant airborne particulate levels without slurry creation | ROI impak: Avoids regulatory fines; preserves worker health and site cleanliness.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Nywerheid Standaard Oplossing | Ons Slag Crusher Plant Oplossing | Voordeel (% Verbetering) |
| : | : | : | : |
| Tonnage Deurset| Standard aggregate crusher adapted for slag | Purposebuilt with reinforced rotors/jaws & optimized flow design| +1525% sustained throughput |
| Liner Wear Life| Standard manganese steel in critical zones| Multilayer wear packages with replaceable sections in all abrasion zones| +80120% verlengde dienslewe |
| Metaalherwinningskoers| Manual picking or postprocess magnetic separation| Inline magnetic separation integrated into crushing circuit| +95% ferrous recovery efficiency |
| Kragverbruik per ton| Vaste spoed dryf oor alle motors| PLCcontrolled variable frequency drives (VFD's) op vervoerbande & aanhangers| 1015% energie gebruik |
| Gemiddelde tyd tussen mislukking (MTBF)| Reactive maintenance schedules based on runtime| Predictive maintenance enabled by vibration & thermal sensors on major bearings| +30% increased MTBF |

5. TEGNIESE SPESIFIKASIES

Kapasiteitsreeks: Konfigureerbaar vanaf 50 TPH tot verby 300 TPH of raw slag feed.
Kragvereistes: Totale gekoppelde vrag vanaf 150 kW aan 800 kW afhangende van konfigurasie; standard supply at 415V/50Hz/3Phase (ander spannings beskikbaar).
Materiaalspesifikasies: Primary crusher jaws manufactured from Mn18Cr2 alloy steel; liner plates from AR400/500 abrasionresistant steel; structural frames from heavyduty ISMB/ISMC sections.
Fisiese afmetings (Typical Skid): Primêre module ca. L12m x B4m x H5m. Full plant footprint varies with configuration.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 10°C tot +45°C; stofbeskermingsgradering van IP55 vir elektriese panele; can be equipped with coldweather or tropical packages as needed.

6. TOEPASSINGSSCENARIO'S

Steel Mill Slag Yard Retrofit | Uitdaging: A midsized steel mill faced chronic downtime due to abrasive wear in its aging crusher, causing pileup of LD slag and lost metal recovery revenue. Manual hammering was frequently required to clear jammed material.| Oplossing: Installasie van 'n sleutel 120 TPH skidmounted slag crusher plant featuring an extraheavyduty jaw crusher and integrated overband magnet.| Resultate: Behaal konsekwente deurset van 120 TPH. Metal recovery increased by 22%. Jaarlikse instandhoudingskoste het na raming afgeneem 35% due to reduced wear part consumption.

Onafhanklike Slagverwerkingskontrakteur | Uitdaging: A contractor needed a mobile solution to process legacy slag piles at multiple sites but required higher capacity than typical mobile track plants offered.| Oplossing: Deployment of a semimobile modular slag crusher plant on portable skids, allowing relocation between sites with minimal reassembly.| Resultate: Plant was operational at a new site within one week of arrival. Verwerk oor 150,000 tons across three sites with consistent product sizing, enabling premium pricing for clean aggregate.

7. KOMMERSIËLE OORWEGINGS

Our slag crusher plants are offered in clear pricing tiers based on capacity and robustness:

Standaarddiensaanleg (Tot 100 TPH): For processed EAF or granulated slag with consistent feed size.
HeavyDuty Plant (100 – 200 TPH): For mixed BF/BOF slags with higher abrasion potential; includes enhanced wear packages.
Extra HeavyDuty Plant (200+ TPH): For largevolume integrated mills; features duplex crushing stages and full automation.

Opsionele kenmerke: Dust encapsulation cabins, metal scrap cleaning drums (for cleaner scrap), advanced metal detectors, outomatiese smeerstelsels.
Dienspakkette: Uitgebreide waarborgplanne, annual inspection contracts guaranteed spare parts kits based on your projected tonnage.
Finansieringsopsies: We work with accredited partners to offer equipment leasing plans or term loans tailored to capital expenditure cycles common in metallurgical processing industries.

8. Gereelde vrae

1. V: Is your plant compatible with our existing material handling equipment?
A: Ja. Ons ingenieurspan sal u huidige afvoerpunte vir vervoerbandhoogtes tydens die ontwerpfase hersien.

2. V Wat is die verwagte operasionele impak tydens installasie-ingebruikneming?
A Vir aanlegte wat op glybaan gemonteer is, neem tipiese installasie ter plaatse, elektriese verbinding weke. Minimale ontwrigting word verwag aangesien die meeste samestellingstoetse voor aflewering voltooi is

3 V Hoe waarborg jy die beweerde slytasielewe vir komponente?
A Dra lewensduur projeksies is gebaseer op historiese data spesifieke allooi spesifikasies Ons verskaf gewaarborgde minimum tonnemaat syfers vir sleutel slytasie dele ondersteun kommersiële terme

4 V Watter opleiding verskaf aan ons bedryfsinstandhoudingspersoneel?
A We include comprehensive onsite training covering normal operation routine maintenance troubleshooting safety procedures Documentation includes detailed manuals parts lists

5 Q Are there financing options available that align with our fiscal planning?
A Yes We offer several financing structures including operating leases capital leases term loans These can structured match cash flow generation from your recovered materials

6 Q Can the plant handle wet or sticky slag materials?
A While designed primarily dry processing we can incorporate specific design modifications such cascading feed systems non stick liners additional screening stages address challenging material characteristics

7 V Wat is die deurlooptyd vanaf bestellingplasing ingebruikneming?
A Lead times vary capacity customization Typical lead time ranges months Standard configurations may be available shorter periods depending current production schedule