1. فتحة مدفوعة بنقطة الألم

تعد إدارة الخبث بمثابة عنق الزجاجة المستمر مع تكاليف ملموسة. هل تواجه هذه التحديات التشغيلية?
Low Throughput & High Downtime: Inefficient primary crushing and frequent clogging from uncrushable material halt your entire processing line, تكلف الآلاف في الساعة من فقدان الإنتاج والعمالة.
ارتداء المفرط & تكاليف الصيانة: Standard crushers rapidly deteriorate when processing highly abrasive slag, leading to premature failure of liners, المطارق, and rotors. The resulting parts replacement and unplanned maintenance erode your profit margins.
حجم المنتج النهائي غير متناسق: Poorly controlled crushing results in uneven aggregate size distribution, reducing the market value of your slag product and limiting its application in highspecification construction or cement blending.
التعقيد التشغيلي العالي & Risk: Reliance on multiple, nonintegrated units for feeding, سحق, الفحص, and metal recovery increases manpower needs, مخاطر السلامة, ونقاط الفشل المحتملة.

Is your current setup delivering the reliable throughput and product quality required for profitability? الحل يكمن في الهدف slag crusher plant processing plant.

2. نظرة عامة على المنتج

أ slag crusher plant processing plant is a stationary or semimobile integrated system designed specifically for the reduction, الفحص, and separation of metallurgical slag (فرن الانفجار, فرن الصلب). يتحول بشكل كبير, irregular slag feed into precisely graded aggregates for sale or further use.

سير العمل التشغيلي:
1. الاستلام الأولي & الفحص المسبق: Runofpile slag is fed via loader into a robust hopper with a grizzly section to bypass fine material.
2. أساسي & Secondary Size Reduction: A heavyduty jaw crusher performs initial breaking. A secondary impactor or cone crusher then reduces the material to the target size range.
3. فحص المواد & تصنيف: Vibrating screens separate crushed material into specified product fractions (على سبيل المثال, 05مم, 510مم, 1020مم).
4. استعادة المعادن (خياري): Overband magnets or magnetic head pulleys extract remaining ferrous metal from the crushed stream for recycling revenue.
5. التخزين & إرسال: Graded aggregates are conveyed to designated stockpiles for loadout.

نطاق التطبيق: معالجة خبث الفرن العالي (بفس), سرقة السكتة الدماغية (السكتة الدماغية LD), خبث السبائك الحديدية, وغيرها من المجاميع المعدنية اللافلزية.
القيود الرئيسية: Not designed for primary rock mining or processing extremely hard virgin rock; optimal performance requires feed material within specified hardness (مقياس موس) and size parameters.

3. الميزات الأساسية

HeavyDuty Reciprocating Plate Feeder | الأساس الفني: Controlled volumetric flow with adjustable stroke | المنفعة التشغيلية: Ensures even, chokefree material delivery to the primary crusher, preventing surges and overloads | تأثير عائد الاستثمار: Eliminates crusher stalls; increases overall plant throughput by up to 25% versus vibratory feeders in sticky slag conditions.

Manganese Steel Crusher Liners | الأساس الفني: Workhardening austenitic manganese steel construction | المنفعة التشغيلية: Liners gain hardness upon impact, dramatically extending service life under severe abrasion | تأثير عائد الاستثمار: يقلل من تكرار استبدال الخطوط الملاحية المنتظمة 4060%, lowering parts inventory costs and maintenance downtime.

Integrated Metal Separation System | الأساس الفني: Permanent overband magnet with selfcleaning belt | المنفعة التشغيلية: Automatically recovers residual tramp metal during processing | تأثير عائد الاستثمار: Generates ancillary revenue from scrap metal; protects downstream crushers from damage; improves final product purity.

نظام التحكم المركزي PLC | الأساس الفني: وحدة تحكم منطقية قابلة للبرمجة مع واجهة الإنسان والآلة (واجهة المستخدم البشرية) لوحة | المنفعة التشغيلية: Allows singleoperator monitoring and control of entire plant flow from a protected cabin | تأثير عائد الاستثمار: يقلل من متطلبات العمل; enables quick troubleshooting; provides production data for efficiency analysis.

تصميم وحدات SkidMounted | الأساس الفني: Preassembled structural steel skids for major components | المنفعة التشغيلية: Significantly reduces onsite civil work and installation time | تأثير عائد الاستثمار: يخفض تكاليف التثبيت بحوالي 30% and allows for potential relocation or plant expansion.

HeavyDuty Vibrating Screens with Deck Guards | الأساس الفني: HighG force exciters and easily replaceable deck panels | المنفعة التشغيلية: Provides consistent sizing efficiency even with damp or fine slag materials; guards contain fly rock | تأثير عائد الاستثمار: Ensures onspec product yield exceeding 95%, maximizing sales value; يعزز سلامة المشغل.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (دائرة التكسير الأساسية) | الحل الخاص بنا لمحطة كسارة الخبث | ميزة (% تحسين) |
| : | : | : | : |
| System Uptime| ~7580% (frequent stops for clearing,jams) |>92% (engineered flow control) |>15% تحسين |
| حياة الخطوط الملاحية المنتظمة في الكسارة الأولية| 6090 أيام (المنغنيز القياسي) |>180 أيام (premium/workhardening) |>100% تحسين |
| Tons Processed per ManHour| Lower due to multipoint operation |>25% higher (centralized control) |>25% تحسين |
| معدل استرداد المعادن| Manual picking or basic magnet |>99% ferrous recovery (optimized placement) |>30% Improvement in purity/revenue |
| تثبيت & وقت التشغيل| 812 أسابيع (field assembly) |>57 أسابيع (modular skid design) |>~40% Reduction |

5. المواصفات الفنية

قدرة المعالجة: قابلة للتكوين من 50 لأكثر من 300 طن في الساعة (الهيدروكربونات النفطية في الساعة).
متطلبات الطاقة: يتراوح إجمالي الحمل المتصل عادةً من 150 كيلوواط ل 450 كيلوواط اعتمادا على تكوين المصنع; supplied at 415V/50Hz or customized.
مواصفات المواد: مصنوعة من الفولاذ الهيكلي S355JR; critical wear components in AR400 abrasionresistant steel and Grade I manganese steel.
خيارات الكسارة الأولية: Jaw Crusher sizes from 750x500mm up to 1200x1000mm feed opening.
خيارات كسارة الثانوية: كسارة الصدم (for less abrasive BFS) up to Ø1400mm rotor diameter, or Cone Crusher (for highly abrasive steel slag).
Screen Specifications: Single or doubledeck vibrating screens from 1800x4800mm up to 2400x6000mm.
نطاق التشغيل البيئي: مصمم لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +45 درجة مئوية; dust suppression spray systems are standard.

6. سيناريوهات التطبيق

Integrated Steel Plant – Slag Processing Yard Challenge:

A major steel producer was landfilling LD converter slag due to an inefficient old crushing circuit that produced inconsistent aggregate sizes and suffered constant hammer wear in the impactor.

حل:

Implementation of a turnkey slag crusher plant processing plant featuring a deepchamber jaw crusher for primary reduction followed by a robust cone crusher for secondary crushing. A twostage screening system was integrated with powerful overband magnets.

نتائج:

The plant achieved a consistent product yield of over 200 TPH of highvalue aggregate sold to the local cement industry. Metal recovery increased revenue by an additional $50k annually. Planned maintenance intervals extended from monthly to quarterly.

Independent Aggregate Producer – Diversification

تحدي:
A traditional quarry operator sought to diversify into industrial byproduct processing but needed a system capable of handling highly variable feed sizes without constant reconfiguration.

حل:

A semimobile slag crusher plant on skids with a heavyduty apron feeder was selected alongside an impact crusher with hydraulic adjustment for quick product size changes.

نتائج:

The operator could now process both purchased demolition concrete و sourced steelworks slag using one flexible unit. Changeover between materials takes less than two hours through hydraulic settings adjustments only.

7. الاعتبارات التجارية

Our solutions are offered across three tiers:

1. Standard Configuration Plant ($250k $500k):
Includes core modules—feeder, primary jaw crusher,شاشة تهتز,and conveyors—for basic sizing operations.Optional features include magnetic separator,dust suppression kit,and starter motor controls package.Service package includes commissioning plus oneyear parts warranty.

2.
3.Enhanced Recovery Plant ($500k $900k):
Adds secondary cone/impactor crushers,a multideck sizing screen,and automated metal separation systems.Optional features include finished product washing systems,tramp iron protection devices,and advanced PLC automation.Service package extends warranty coverage plus annual preventive maintenance inspections.Financing options available through partner institutions include equipment leasing plans starting at $8k/month.

4.مرفق المعالجة الجاهزة ($900ك+):
Fully integrated system including receiving hoppers,surge bins,total dust collection enclosure,and automated weighloading out system.Custom engineering available.Optional features include remote monitoring via SCADA systems.Service package includes full operational training,a dedicated service manager,and guaranteed spare parts delivery within agreed terms.Comprehensive project financing can be structured based on client credit profile.

\Financing terms subject to credit approval.Please inquire directly regarding current rates.

التعليمات

1.س:What types of raw feed size can your standard plants accept?
أ:The standard primary jaw configuration accepts feed lumps up to ~650mm edge length.Larger inlet sizes are available as an option.Precrushing may be advised if runofpile chunks exceed this dimension consistently

2.س:What is the typical lead time between order placement commissioning?
A.For standard configurations lead time is typically between16and24weeks.This covers manufacturing,اختبار المصنع,and shipment.Modular skid design reduces site installation time significantly compared traditional builtinplace plants

3.س:What ongoing maintenance does this equipment require?
A.Daily visual inspections weekly greasing checks are required.Major planned maintenance involves periodic liner replacements based actual wear rates which we help predict using historical field data.A comprehensive preventive schedule provided

4.Q.How does this integrate with our existing conveyor stockpile system?
A.The plants are designed as complete circuits but can be adapted tie into existing infrastructure.We require details regarding existing conveyor heights capacities ensure proper interface engineering during design phase

5.Q.What kind power supply needed operate typical200TPHplant?
A.A200TPHslag crushing screening circuit typically requires total connected load approximately300kW.We recommend consulting local electrical engineer ensure adequate supply transformer capacity softstart systems minimize grid disturbance

6.Q.Are spare parts readily available long after purchase?
A.All critical wear parts common consumables stocked our central warehouse.We provide recommended initial spare parts list order ensure minimal downtime guarantee availability support throughout equipment lifecycle

7.Q.What aftersales service support included?
A.All installations include commissioning supervision operator training period.We offer tiered service contracts ranging emergency breakdown support scheduled preventive maintenance visits full annual inspection programs