1. PYNPUNT GEDREWE OPENING

Die bestuur van slak, a challenging byproduct of metal production, directly impacts your plant’s bottom line and operational continuity. Staan jy voor hierdie aanhoudende uitdagings?
Onbeplande stilstand: Frequent breakdowns of underengineered crushers halt your entire material handling chain, costing thousands per hour in lost processing time and labor.
Oormatige dra & Onderhoudskoste: The highly abrasive nature of slag rapidly degrades standard crushing components, lei tot onvolhoubare besteding aan vervangingsonderdele en instandhoudingsarbeid.
Inkonsekwente uitset & Knelpunte: An illmatched crusher produces uneven particle size distribution, causing downstream screening inefficiencies and storage issues, ultimately delaying shipment to your customers.
Hoë bedryfskoste: Inefficient power consumption and the need for secondary or even tertiary crushing stages erode profit margins on what should be a valuable recycled product.

Die sentrale vraag vir aanlegbestuurders is: how do you transform this abrasive liability into a consistent, profitable stream without compromising reliability? Die oplossing lê daarin om 'n doelgebou te spesifiseer slakbrekeraanleg.

2. PRODUK OORSIG

A slakbrekeraanleg is a stationary or semimobile system engineered specifically to reduce large chunks of aircooled or granulated metallurgical slag into precisely graded aggregates. Unlike generic rock crushers, it is designed from the ground up to withstand extreme abrasion and intermittent tramp metal.

Operasionele werkvloei:
1. Primêre Ontvangs & Voeding: Slag is delivered via dump truck or loader into a robust hopper, often equipped with a grizzly feeder to bypass subsize material and protect the primary crusher.
2. Primêre groottevermindering: ’n Swaardiens-kaakbreker of impakbreker voer die aanvanklike drukwerk uit, reducing large slabs to manageable diameters (tipies <200mm).
3. Sekondêre verplettering & Sifting: Material is conveyed to a secondary cone or impact crusher for further reduction. The crushed output is then screened via vibrating screens to separate product into specified size fractions (bv., 05mm, 510mm, 1020mm).
4. Materiaalhantering & Voorraad opgaar: Onspec aggregate is conveyed to designated stockpiles for loading and transport. Oversize material is recirculated back to the secondary crusher in a closedloop system.

Toepassingsomvang: Designed for ferrous (hoogoond, staal) en nie-ysterhoudend (koper, lei) slags. Ideal for integrated metal plants and standalone slag processing yards.
Beperkings: Not suitable for primary ore processing or extremely hard igneous rock. Voergrootte moet volgens plantontwerpspesifikasies beheer word.

3. KERNKENMERKE

HeavyDuty skuurbestande voerings | Tegniese basis: Highchrome white iron or manganese steel castings | Bedryfsvoordeel: Liner lewe het met 60100% in vergelyking met standaard materiale, drastically reducing changeout frequency | ROI impak: Lowers costperton for wear parts and reduces maintenance downtime by up to 30% jaarliks.

Tramp metaalbeskermingstelsel | Tegniese basis: Hydraulic or pneumatic release mechanisms on crushers; metal detectors on feed conveyors | Bedryfsvoordeel: Prevents catastrophic damage from uncrushable metals mixed within slag | ROI impak: Eliminates risk of major rotor or shaft damage, protecting a capital asset worth hundreds of thousands.

PLCBased Automated Control Panel | Tegniese basis: Centralized programmable logic controller with load management and fault diagnostics | Bedryfsvoordeel: Aktiveer enkeloperateurbeheer, optimaliseer kragverbruik, and provides clear alarm indicators for rapid troubleshooting | ROI impak: Reduces labor requirements and minimizes unplanned stops through predictive alerts.

Modulêre SkidMounted Ontwerp | Tegniese basis: Vooraf gemonteerde struktuurstaalstrokies vir hoofkomponente | Bedryfsvoordeel: Significantly reduces civil works and onsite installation time by up to 40% | ROI impak: Faster commissioning gets your revenuegenerating operation online sooner with lower initial construction costs.

HeavyDuty Vibrerende Grizzly Voeder | Tegniese basis: Robust feeder with adjustable grizzly bars for prescreening | Bedryfsvoordeel: Removes fines prior to primary crushing, increasing throughput efficiency and reducing unnecessary wear on the primary chamber | ROI impak: Improves overall plant capacity by 1525% while lowering energy consumption per ton.

Ingeslote stofonderdrukkingstelsel | Tegniese basis: Strategically placed spray nozzles at transfer points coupled with dust extraction vents | Bedryfsvoordeel: Maintains compliant airborne particulate levels, ensuring a safer working environment and meeting regulatory standards | ROI impak: Vermy potensiële boetes en werkonderbrekings as gevolg van omgewingsversuim.

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Bedryfstandaard (Generiese Crusher Plant) | Ons Slag Crusher Plant Oplossing | Voordeel (% verbetering) |
|||||
| Dra Part Life (Primêr) | 3045 Dae | 6090 Dae | +100% |
| Stelsel Uptime Beskikbaarheid | 8085% | 9295% | +12% |
| Power Consumption/Ton | Basislyn | Geoptimaliseerde motorladings & efficient drive design |18% |
| Opbrengs van voltooide produk | Variable sizing requiring recrush Consistent grading within spec bands Recrush volume reduced by ~25% |
| Installasie & Ingebruikneming| 812 Weke 57 Weke 40% timetooperation |

5. TEGNIESE SPESIFIKASIES

Verwerkingskapasiteit: Konfigureerbaar vanaf 50 TPH tot verby 300 TPH.
Voergrootte Maksimum: Up to 800mm slab size (model afhanklik).
Kragvereistes: Totale gekoppelde vrag wissel gewoonlik van 150 kW aan 450 kW; designed for standard industrial voltage supply (400V/50Hz of pasgemaak).
Breker spesifikasies: Primary jaw crusher sizes from 750x500mm up to 1200x1500mm; Secondary cone crushers with heavyduty mantle/bowl liners.
Materiaalspesifikasies: Crusher housings in fabricated steel plate; Liners in Mn18Cr2 / HighChrome Allooi; Conveyor belts with high abrasionresistant covers.
Fisiese afmetings (Tipiese opstelling): Footprint approximately 40m (L) x 20m (W). Skid designs minimize foundation needs.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 20°C tot +45°C; stofonderdrukkingstelsel gegradeer vir effektiewe werking tot 80% relatiewe humiditeit.

6. TOEPASSINGSSCENARIO'S

Geïntegreerde Staal Plant Slag Yard Herwinning

Uitdaging: A major steel producer faced escalating landfill costs for blast furnace slag and needed an onsite solution creating saleable aggregate. Their existing equipment suffered weekly liner failures.
Solution Implementation of a turnkey slakbrekeraanleg featuring primary jaw crushing followed by secondary cone crushing with automated screening.
Results Achieved consistent production of three aggregate grades within six weeks of commissioning. Wear part lifecycle extended from three weeks to seven weeks. The operation converted a cost center into a profit stream within one year.

Onafhanklike Slagverwerkingskontrakteur

Challenge A contractor processing slag from multiple sources required high mobility between sites without sacrificing durability or capacity.
Solution A semimobile skidmounted slakbrekeraanleg, where primary and secondary modules could be relocated independently via lowloader trailers.
Results Reduced site setup time from three weeks to five days per location through prewired modules. Plantbeskikbaarheid oorskry 93%, allowing the contractor to fulfill multiple longterm supply contracts reliably.

7. KOMMERSIËLE OORWEGINGS

Our solutions are offered in clear pricing tiers based on capacity:
Vlak I (200 TPH): Fully customized highvolume systems with advanced automation options.

Optional features include magnetic separators for residual metal recovery automated greasing systems remote monitoring telemetry packages extended dust control enclosures

Service packages range from basic preventive maintenance plans comprehensive annual service contracts including wear part supply financing options are available including leaseto own structures equipment loans tailored support project cash flow

8.Gereelde vrae

What types of slag are suitable?
Designed primarily aircooled blast furnace basic oxygen furnace steel slags copper smelter slags Granulated slags may require specific feed arrangements due density

How does handle tramp metal?
Systems incorporate multiple protection layers including hydraulic release mechanisms primary jaw optional metal detectors feed conveyor automatically stop belt uncrushable object detected

Watter tipiese afleweringstydinstallasie?
For standard configurations lead time manufacturing ranges months Complete delivery installation commissioning typically completed weeks following arrival site

Can integrate existing conveyors screens?
Yes plants engineered modular basis can interface existing downstream equipment provided specifications match Our engineering team will review layout compatibility

What ongoing maintenance requirements?
Daily visual checks lubrication Weekly bolt tightening inspections Scheduled liner replacements based monitored wear rates Predictive maintenance data provided via control system alerts