1. PAINPOINT DRIVE NOLEING

Are you managing the significant cost and complexity of slag byproduct from your metallurgical operations? Тохиромжгүй тэжээлийн хэмжээ, зүлгүүрийн материал, and the need for precise final grading create persistent challenges for plant managers. Common issues include premature wear on crusher components leading to excessive maintenance downtime, inefficient processing that fails to liberate all valuable metals, and a lack of flexibility to handle varying slag types or production demands. This results in lost revenue from unrecovered material, high operational costs for parts and labor, and bottlenecks in your overall material handling circuit. Are you seeking a solution that delivers consistent throughput, maximizes metal recovery, and reduces your total cost of ownership? Аг bespoke slag crusher plant is engineered to address these exact operational and financial pressures.

2. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ

Аг bespoke slag crusher plant is a customengineered stationary or semimobile crushing system designed specifically for the size reduction and liberation of metallurgical slag (тэсэлгээний зуух, болд, зэс, гэх мэт.). Unlike standard aggregate crushers, it is configured for extreme abrasion resistance and tailored to the specific chemical and physical properties of your slag stream.

Үйл ажиллагааны ажлын урсгал:
1. Анхдагч хүлээн авах & Урьдчилсан үзлэг: Slag is fed via excavator or loader into a heavyduty vibrating grizzly feeder, нарийн материалыг арилгадаг (40мм) bypassing the primary crusher.
2. Нийт хэмжээг бууруулах: Хэт том материал нь бат бөх анхдагч бутлуурт ордог (ихэвчлэн эрүү эсвэл цохилтын төрөл) to break down large slabs and chunks.
3. Хоёрдогч бутлах & Чөлөөлөлт: Материалыг хоёрдогч бутлуурт дамжуулдаг (often a cone or impactor) цаашид бууруулах зорилгоор, optimally liberating encapsulated metal from the slag matrix.
4. Металл тусгаарлалт & Эцсийн хэмжээ: Crushed product passes over magnetic separators (overband or drum) хар металл олборлох. Subsequent screening decks classify the crushed slag into precise commercial grades (жишээ нь e., 05мм, 520мм).

Хэрэглээний хамрах хүрээ & Хувьсгал:
This plant is designed for processing cooled, solidified metallurgical slag. It is not suitable for molten slag or nonmetallic industrial byproducts without significant reengineering. Maximum feed size and final capacity are determined during the bespoke design phase based on clientspecific feedstock analysis.

3. ҮНДСЭН ОНЦЛОГ

Хүнд даацын хормогч тэжээгч | Техникийн үндэслэл: Overlapping manganese steel flights driven by rugged crawler tractors | Үйл ажиллагааны ашиг тус: Handles direct tipping of large, abrasive slag pieces with minimal wear and consistent feed rate to the primary crusher | ROI нөлөө: Eliminates feeder damage common with standard plate feeders, reducing unplanned stoppages and replacement costs by an estimated 60%.

Primary Jaw Crusher with Wedge System | Техникийн үндэслэл: Deep crushing chamber with steep nip angle and hydraulic toggle adjustment | Үйл ажиллагааны ашиг тус: Effectively processes slabby slag with high compressive strength; hydraulic adjustment allows quick setting changes for varying feed or product requirements | ROI нөлөө: Increases availability through faster setting changes and provides up to 15% better throughput on abrasive materials versus standard designs.

HighStrength Liner Alloys | Техникийн үндэслэл: Austenitic manganese steel with carbide additions or composite ceramic inserts in highwear zones | Үйл ажиллагааны ашиг тус: Extends liner life in both primary and secondary crushing chambers exposed to highly abrasive slag | ROI нөлөө: Directly reduces consumable parts expenditure; талбайн өгөгдөл харуулж байна a 40100% increase in liner life compared to standard manganese steel.

Нэгдсэн соронзон тусгаарлах хэлхээ | Техникийн үндэслэл: Strategic placement of selfcleaning overband magnets and drum magnets on transfer points postcrushing | Үйл ажиллагааны ашиг тус: Maximizes recovery of liberated ferrous metal continuously during operation without manual intervention | ROI нөлөө: Captures additional revenue stream from scrap metal; improves final product purity for highervalue aggregate sales.

Төвлөрсөн PLC хяналт & Хяналтын систем | Техникийн үндэслэл: Programmable Logic Controller with HMI touchscreen providing realtime amp draws, даацын температур, and production totals | Үйл ажиллагааны ашиг тус: Gives operators immediate insight into plant health and performance, enabling predictive maintenance and quick diagnosis of faults | ROI нөлөө: Гамшигт эвдрэлийг багасгадаг; үйлдвэрлэлийн туршилт нь боломжуудыг харуулж байна 30% reduction in troubleshooting time.

Modular Skid or TrackMounted Design | Техникийн үндэслэл: Plant sections built on heavyduty structural skids or mobile tracks | Үйл ажиллагааны ашиг тус: Offers flexibility for future site relocation or phased expansion with reduced civil works cost and faster installation | ROI нөлөө: Lowers capital investment in permanent infrastructure by up to 25% and shortens commissioning time.

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт (Ерөнхий дүүргэгч үйлдвэр) | Bespoke Slag Crusher Plant Solution | Давуу тал (% Сайжруулалт) |
| : | : | : | : |
| Liner Life (Чухал)| Стандарт 14% Mn Steel | Custom Alloy/Composite Liners | +40% нь +100% |
| Металл сэргээх хурд| Postcrushing magnetic separation only | Integrated multistage magnetic separation at optimal liberation points| +15% нь +25% сэргээх |
| Үйлдвэрийн хүртээмж| Reactive maintenance schedule; manual greasing points| PLC monitoring with predictive alerts; centralized autolubrication| +8% нь +12% үргэлж ажиллах |
| Нэг кВт/ц тонн| Fixedspeed drives; nonoptimized flow| Loadresponsive VFDs on conveyors; optimized chamber designs| +5% нь +10% бүтээмж |
| Дахин тохируулах хугацаа| Welded structures; fixed layouts| Modular skids with flanged connections; adjustable crusher settings| 50% downtime for changes |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Хүчин чадлын хүрээ: -аас тохируулах боломжтой 50 TPH хэтэрсэн 400 TPH of inlet slag.
Уургийн хэмжээ: Accepts slab feed up to 1000mm x 1500mm (subject to primary crusher selection).
Эрчим хүчний шаардлага: Total installed power typically between 250kW – 800kW based on configuration; supplied for 400V/50Hz or other regional standards.
Үндсэн материалын үзүүлэлтүүд: Primary frame – S355JR structural steel; Highwear hoppers/liners – Hardox 450/500 or equivalent; Crusher jaws/mantles – Premium modified manganese steel.
Физик хэмжээсүүд: Highly variable per design. A typical skidmounted primary section may be approx. L15m x W4m x H6m.
Байгаль орчны үйл ажиллагааны хүрээ: Тохиромжтой тосолгооны системээр 20°С-аас +45°C хүртэлх орчны температурт зориулагдсан. Dust suppression spray systems are standard at transfer points.

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

Integrated Steel Mill Slag Processing Yard Challenge:

A major steel producer faced escalating landfill costs for aged blast furnace slag banks while losing revenue from unrecovered scrap metal within the piles.
Хариу:
Implementation of a semimobile bespoke slag crusher plant featuring a primary jaw crusher followed by an impactor for cubical shaping.
Үр дүн:
Үйлдвэрийг дахин боловсруулсан 1.2 million tons of stockpiled slag annually into highvalue railway ballast aggregates while recovering an additional €180k/year in ferrous scrap metal previously landfilled.

Copper Smelter Byproduct Valorization Challenge:

A smelter needed consistent processing of granulated copper slag into fine sand substitute but struggled with variable hardness causing frequent blockages in their existing system.
Хариу:
A bespoke twostage vertical shaft impactor (Бүгд) plant was engineered specifically for granulated copper's abrasiveness.
Үр дүн:
Achieved consistent production of minus6mm sand meeting construction specifications at >95 TPH reliability while reducing specific wear costs by over €0.12 per ton processed compared to prior equipment.

7. АРИЛЖААНЫ ХЭРЭГЛЭЭ

Үнийн шатлал: Investment varies significantly based on capacity automation level
Үндсэн тохиргоо (150 Цагдаа): Includes primary/secondary crushing core modules basic screening magnetic separation
Сайжруулсан тохиргоо (+20%) Adds automated lubrication advanced dust control system PLC control panel
Түлхүүр гардуулах шийдэл (+3550%) Includes civil works design installation commissioning training

Нэмэлт шинж чанарууд: Metal detector prior tertiary crushing module automated sampling system remote monitoring telemetry water recycling system

Үйлчилгээний багцууд: Annual inspection parts supply agreements full maintenance contracts operator training programs

Санхүүжилтийн сонголтууд: Equipment leasing capital expenditure financing through partner institutions payperton processing agreements can be structured

8.Түгээмэл асуултууд

What analysis do you require design my bespoke slug crushеr plаnt?
We require representative sample(s) your slug fоr laboratory testing determine its compressive strength abrasiveness index bulk density chemical composition Accurate feed rate target product sizes are also critical

How does а bespokе plаnt improve my metаl recоvery rаte over а retrofit solution?
Thе key strategic placement оf magnetic separators immediately after each crushing stage where liberation occurs Our design ensures maximum exposure оf liberated metаl tо thе magnetic field аt thе correct material depth оn thе belt which retrofit solutions often compromise

What iѕ thе typicаl delivery аnd commissionіng timeline fоr such custom equipment?
Following detailed engineering approval lead times range frоm months fоr skid mounted plants Site commissioning including mechanical erection electrical connection process optimization typically requires weeks depending оn site readiness

Are spare parts readily available given thе custom nature оf thе equipment?
While thе layout iѕ custom core components (crushers screens motors drives) аrе selected frоm globally recognized OEMs ensuring parts availability Our supply agreement includes detailed bill оf materials аnd recommended local stockholding fоr critical wear items

Can thiѕ plаnt bе relocated іf my operаtions move?
Yes Thе modular skid design iѕ explicitly engineered fоr relocation Each major module can bе disconnected transported reassembled аt new site significantly preserving уour initial capital investment compared tо fixed foundation plants