1. فتحة مدفوعة بنقطة الألم

Managing slag stockpiles presents persistent operational and financial challenges. Are you contending with inefficient manual breaking methods that bottleneck your material flow? Does inconsistent feed size from primary crushing reduce your downstream screening and separation efficiency, leading to valuable metal loss? Are you facing excessive wear on crusher components from abrasive slag, driving up maintenance costs and unplanned downtime? The costs of slow processing, high consumable expenses, and metal recovery inefficiency directly impact your site’s profitability. How can you transform this byproduct into a consistent, highvalue aggregate stream while controlling operational expenditure? The solution requires a purposeengineered system designed for the specific demands of slag reduction.

2. نظرة عامة على المنتج

أ مصنع كسارة الخبث is a stationary or semimobile processing system engineered specifically for the size reduction of aircooled blast furnace (فرنك بلجيكي) slag or steel slag. Its core function is to crush large slag lumps into precisely graded aggregates for use in construction, بناء الطريق, or as a feedstock for further metal recovery processes.

سير العمل التشغيلي:
1. يٌطعم & الفحص المسبق: Slag is loaded via excavator or loader into a robust feed hopper, often with a grizzly section to bypass fine material.
2. سحق الابتدائي: A heavyduty jaw crusher or impact breaker reduces large lumps (often up to 1m+) إلى حجم يمكن التحكم فيه.
3. تحويل & سحق الثانوية: يتم نقل المواد إلى كسارة ثانوية (typically a cone crusher or impact crusher) for further refinement to the target product size.
4. التحجيم & الانفصال: Crushed material passes through vibrating screens to separate it into specified fractions (على سبيل المثال, 05مم, 510مم, 1020مم). Magnetic separators are often integrated at this stage to extract remaining ferrous metal.
5. التخزين: Graded aggregates are conveyed to designated stockpiles for dispatch.

نطاق التطبيق: مثالية لمصانع الصلب المتكاملة, ساحات معالجة الخبث المستقلة, وإجمالي المنتجين المتخصصين في المنتجات الثانوية الصناعية.
القيود: Not designed for molten slag; feed material must be aircooled and solid. Performance is contingent on proper feed size control and the specific abrasiveness and composition of the source slag.

3. الميزات الأساسية

تكوين كسارة الثقيلة | الأساس الفني: Manganese steel jaws/liners with optimized crushing chamber geometry | المنفعة التشغيلية: Sustained high throughput of highly abrasive material with reduced risk of premature failure | تأثير عائد الاستثمار: Lower costperton crushed via extended wear life and reduced frequency of liner changes.
Integrated Metal Recovery System | الأساس الفني: Overband magnetic separators positioned at key discharge points | المنفعة التشغيلية: مستمر, automated extraction of residual ferrous metal from the aggregate stream | تأثير عائد الاستثمار: Creates an additional revenue stream from recovered scrap metal while protecting downstream equipment from tramp metal damage.
Vibration Dampening Base Frame | الأساس الفني: Reinforced steel frame with antivibration mounts for major components | المنفعة التشغيلية: Minimizes structural stress and transmitted vibration, ensuring stable operation and reducing foundation requirements | تأثير عائد الاستثمار: Lowers installation complexity and cost, enhances longterm structural integrity of the plant.
التشحيم المركزي & نقاط المراقبة | الأساس الفني: Manifolded lubrication lines for all major bearing points | المنفعة التشغيلية: تمكن آمنة, efficient routine maintenance without requiring access to multiple isolated points during operation | تأثير عائد الاستثمار: Reduces lubrication time by up to 50%, promotes bearing health, and decreases unscheduled downtime.
Adjustable Discharge Setting System | الأساس الفني: Hydraulic or mechanical adjustment on secondary/tertiary crushers | المنفعة التشغيلية: Allows operators to quickly change final product sizing to meet different market specifications | تأثير عائد الاستثمار: Enables rapid response to changing customer demands, maximizing plant utilization and sales opportunities.

4. المزايا التنافسية

| مقياس الأداء | Industry Standard Slag Processing | الحل الخاص بنا لمحطة كسارة الخبث | ميزة (% تحسين) |
| : | : | : | : |
| الحمولة الإنتاجية (مادة كاشطة)| عامل, often declines with liner wear| Consistent output maintained via optimized wear part design & تدفق| حتى 1520% more consistent yield over liner life |
| كفاءة استعادة المعادن| Singlestage magnetic separation, often manual cleaning| Multistage magnetic separation at optimal transfer points| Ferrous recovery rates improved by 2530% |
| توقف الصيانة (المقرر)| Dispersed lube points; manual setting adjustment| Centralized systems & hydraulic adjustment features| Routine service time reduced by approximately 40% |
| اتساق شكل المنتج| Basic crushing circuits can produce flaky aggregates| Chamber optimization & crushing stage matching produces more cubical product| Improved cubicity index enhances aggregate value for premium applications |

5. المواصفات الفنية

نطاق السعة: قابلة للتكوين من 50 الهيدروكربونات النفطية لأكثر من 300 الهيدروكربونات النفطية في الساعة, depending on feed size and required product grading.
متطلبات الطاقة: يتراوح إجمالي الطاقة المثبتة عادةً من 150 كيلوواط ل 600 كيلوواط, supplied by mains connection or onboard diesel generator set for semimobile units.
مواصفات المواد: Primary wear components (بطانات, impeller bars) manufactured from highchrome martensitic steel or premium manganese steel. Structural frames use heavyduty rolled steel sections.
الأبعاد المادية (الإعداد النموذجي): Footprint varies by capacity; أ 150 TPH plant may require approximately 25m (ل) × 18 م (دبليو) × 12 م (ح).
نطاق التشغيل البيئي: مصمم لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +45 درجة مئوية. Dust suppression systems are standard to maintain environmental compliance.

6. سيناريوهات التطبيق

ساحة الخبث المتكاملة لمصنع الصلب | تحدي: Inefficient primary breaking causing backlog; low recovery of valuable metallics from old slag dumps leading to lost revenue. | حل: Deployment of a turnkey Slag Crusher Plant with highcapacity jaw crusher for primary reduction and two stages of magnetic separation. | نتائج: Processing rate increased to 180 الهيدروكربونات النفطية في الساعة; recovered an average of 8 tons of ferrous metal per operating day; cleared legacy stockpile within projected timeline.

Commercial Aggregate Producer Specializing in Industrial Byproducts | تحدي: Existing plant struggled with extreme abrasiveness of steel slag, resulting in unsustainably high wear part costs and poor product shape limiting marketability.| حل: Installation of a purposebuilt Slag Crusher Plant featuring specialized abrasionresistant liners and a cone crusher secondary stage for improved particle shape.| نتائج: Wear part lifecycle extended by over 60%; produced highquality cubical aggregate meeting road base specifications; opened access to highervalue construction contracts.

7. الاعتبارات التجارية

يتم تقديم محطات كسارة الخبث لدينا في ثلاثة مستويات أساسية:
التكوين القياسي: A robust base plant covering primary crushing, basic screening/conveying, and singlestage magnetic separation.
تكوين الاسترداد المحسن: Adds secondary crushing for finer grading optimization and multistage magnetic separation drums/scanners.
Fully Modular/Mobile Configuration: Skidmounted or trailerbased units offering shorter installation times and relocation flexibility.

Optional features include automated dust suppression systems, advanced vibration monitoring sensors, حزم توليد الطاقة على متن الطائرة, and custom conveyor lengths.

We provide comprehensive service packages ranging from annual inspection plans to fullturnkey operation & عقود الصيانة. Financing options including leasing structures are available through our partners to facilitate capital expenditure planning.

8. التعليمات

1. Is your Slag Crusher Plant compatible with our existing conveyors and screening equipment?
نعم; our engineering team designs the transfer heights and discharge points based on your site layout survey data provided during quotation.

2. What is the expected operational impact on our power consumption?
Field data shows that an optimized plant design uses energy more efficiently per ton processed than piecemeal systems due to reduced recirculation loads.

3. How does pricing typically scale with capacity?
Pricing follows an economyofscale curve but is also influenced by specific requirements like level of metallurgical recovery needed or environmental enclosures.

4. ما هي الشروط التجارية القياسية المقدمة?
We typically offer FOB pricing exworks alongside CIF quotations for international buyers; payment terms are structured around project milestones such as FAT (اختبار قبول المصنع).

5.