1. PAINPOINT DRIVE NOLEING

Managing slag is a critical yet costly bottleneck in modern metal production and recycling. Inefficient processing directly impacts your bottom line through equipment wear, lost revenue from unrecovered metallics, and escalating disposal costs. Та эдгээр байнгын сорилтуудтай тулгарч байна уу??

High Abrasion Costs: The extreme abrasiveness of slag rapidly degrades standard crusher components, leading to frequent downtime for liner changes and rotor repairs, costing thousands in parts and lost processing hours.
Metallics Recovery Inefficiency: Ineffective liberation of trapped metal beads from the slag matrix means valuable material is sent to waste, representing a direct loss of potential revenue.
Unpredictable Feed & Clogging: Variable slag feed size, чийг агууламж, and the presence of tramp metal can cause frequent jams and unscheduled stoppages, disrupting your entire downstream workflow.
Чандруу & Дуу чимээний зохицуулалт: Processing generates significant dust and noise, creating environmental and health challenges that require costly secondary containment systems to meet regulatory standards.
High Operational Complexity: Equipment that requires constant adjustment and skilled monitoring increases labor costs and the potential for operator error.

A sustainable operation requires a processing solution engineered specifically for these rigors. How do you achieve higher throughput with lower operating costs and maximized resource recovery?

2. БҮТЭЭГДЭХҮҮНИЙ ТОЙМ

The Sustainable Slag Crusher Plant is a heavyduty, integrated processing system designed for the primary and secondary crushing of aircooled or granulated blast furnace (BF) slag and steel slag. It transforms variable feed material into precisely graded aggregates for use in construction or prepares it for further metallic recovery.

Үйл ажиллагааны ажлын урсгал:
1. Тэжээл & Урьдчилсан үзлэг: Incoming slag is fed via apron feeder to a scalping screen, removing fine fractions (10mm) to bypass unnecessary crushing.
2. Анхдагч бутлах & Чөлөөлөлт: Oversize material enters a robust jaw crusher or impact crusher for initial size reduction, effectively fracturing the slag matrix to liberate embedded metallics.
3. Metallic Separation: Crushed material passes over an overhead magnetic separator, extracting ferrous metal for recycling revenue.
4. Хоёрдогч бутлах & Дүгнэлт: The remaining material is conveyed to a secondary cone or impact crusher for final sizing, then to screening decks to produce saleable aggregate fractions (жишээ нь e., 05mm, 510mm, 1020mm).
5. Тоос дарах: An integrated water spray system at transfer points controls dust emissions throughout the process.

Хэрэглээний хамрах хүрээ & Хувьсгал:
Саад тохолтол тарз: Ideal for integrated steel plants, smelters, standalone slag processing yards, and aggregate producers handling BF slag, цус харвалт хулгайлах, and nonferrous slags. Capable of processing feed sizes up to 800mm.
Хувьсгал: Not designed for primary metal shredding or processing of raw ore. Feed material with excessive claylike moisture may require predrying. Maximum hardness should not exceed that of typical slags (Мохс 78).

3. ҮНДСЭН ОНЦЛОГ

Hardox Lined Hopper & Хооллох | Техникийн үндэслэл: Abrasionresistant steel plate construction | Үйл ажиллагааны ашиг тус: Withstands impact from large, sharp slag pieces with minimal deformation or wear | ROI нөлөө: Reduces replacement cycle by up to 300%, lowering longterm capital expenditure on structural components.

HighStrength Rotor with Disc Design | Техникийн үндэслэл: Forged rotor discs with bolton wear parts | Үйл ажиллагааны ашиг тус: Provides exceptional moment of inertia for stable crushing of dense slag; allows for individual replacement of wear parts | ROI нөлөө: Cuts maintenance downtime by up to 40% compared to welded rotor designs.

Гидравлик тохируулга & Цэвэрлэх | Техникийн үндэслэл: Mechanically simple hydraulic cylinders for gap setting and uncrushing | Үйл ажиллагааны ашиг тус: Enables quick adjustment of product grading without stopping the plant; clears blockages in minutes versus hours | ROI нөлөө: Increases plant availability by an estimated 35%, translating directly to higher annual tonnage.

Integrated MultiStage Magnetic Separation | Техникийн үндэслэл: Overband selfcleaning magnet followed by drum magnet on final product conveyor | Үйл ажиллагааны ашиг тус: Maximizes recovery of ferrous metallics at multiple stages postcrushing | ROI нөлөө: Turns waste into revenue; field data shows recovery rates exceeding 98% of liberated metal.

Enclosed Conveying with Spray System | Техникийн үндэслэл: Dusttight conveyor covers paired with solenoidcontrolled water spray nozzles at transfer points | Үйл ажиллагааны ашиг тус: Actively suppresses airborne particulate at the source | ROI нөлөө: Minimizes investment in external bag houses and reduces water consumption by over 60% versus manual spraying.

Төвлөрсөн тослох & Чичиргээний хяналт | Техникийн үндэслэл: Automated lubricant delivery to key bearings; triaxial sensors on crushers and screens | Үйл ажиллагааны ашиг тус: Ensures optimal bearing life; provides early warning of mechanical imbalance or impending failure | ROI нөлөө: Холхивчийн эвдрэлээс урьдчилан сэргийлнэ, reducing unplanned downtime by up to 25%.

Модульчлагдсан SkidMounted дизайн (Сайн дурын) | Техникийн үндэслэл: Preassembled plant sections on heavyduty skids | Үйл ажиллагааны ашиг тус: Dramatically reduces civil works and installation time on site | ROI нөлөө: Can reduce total project commissioning time by weeks, орлого олох хугацааг хурдасгах.

4. ӨРСӨЛДӨХ ДАВУУ ТАЛУУД

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт шийдэл | Sustainable Slag Crusher Plant Solution | Давуу тал (% Сайжруулалт) |
| : | : | : | : |
| Liner Wear Life (Анхдагч crusher) | Manganese Steel Liners (400500 цаг)| Хардокс / Ceramic Composite Liners (1,2001,500 цаг)| ~200% Longer Life |
| Металлын нөхөн сэргээх хурд (% Ferrous)| Singlestage Overband Magnet (~92%)| Twostage Magnetic Separation Circuit (>98%)| ~6% More Revenue Capture |
| Төлөвлөөгүй зогсолт (Annual Hours) due to blockages/mechanical failure| Тооцоолсон 120150 цаг/жил| Тооцоолсон <80 цаг/жил with hydraulic clearing/monitoring| >33% Бууралт |
| Дамжуулагчийн тууштай байдал (Tonnage/hr variance)| +/15% due to feed variation/clogging| +/5% due to optimized flow design/control systems| ~67% More Stable Output |
| Dust Emission at Transfer Points (мг / м³)| >50 mg/m³ without suppression|60% Бууралт |

5. ТЕХНИКИЙН ҮЗҮҮЛЭЛТҮҮД

Боловсронуу тал: -аас тохируулах боломжтой 50 TPH хэтэрсэн 400 Цагдаа.
Feed Size Max: Up to 800mm (загвараас хамаарна).
Final Product Sizes: Adjustable from 05mm sand up to 40mm aggregate.
Цалин зүй: Total installed power ranges from approximately 250 kw (for basic setups) Шалтгаална, хамаарна >800 kw (for highcapacity plants).
Үндсэн материалын үзүүлэлтүүд:
Crusher Liners/Wear Parts: Hardox®/Trellex® or equivalent highabrasion alloys.
Туузан дамжуулагч: ST1000+ rated multiply belts with abrasionresistant covers.
Structural Steelwork:S355JR grade minimum.
Дэлгэцийн тавцан:Piano wire or polyurethane panels depending on application.
Физик хэмжээсүүд (Example MidRange Plant): Ойролцоох. Length x Width x Height =35m x18m x12m
Байгаль орчны үйл ажиллагааны хүрээ: Designed for ambient temperatures from 20°Cto +45°C; dust suppression system effective upto80% relative humidity.

6. ХЭРЭГЛЭЭНИЙ СУРТАЛЧИЛГАА

Integrated Steel Plant Slag Yard Recycling

Сорилт:A major steel producer faced escalating landfill costsfor processedslagand neededto improve metallic yieldfrom their existing aging crushers.Solution:A turnkey Sustainable Slag Crusher Plant was installed parallelto their existing line,focusedon secondary crushingand highefficiency magnetic separation.The new plant featured our twostage magnetic separation circuitand modular skid designfor rapid deployment.Үр дүн: Achieveda99% recovery rateof liberated metallics,increasing annual scrap revenueby$450k.Reducedlandfill volume by65%, saving$220k annuallyin tipping fees.Plant was commissionedin11 weeks due tomodular design.

Independent Construction Aggregate Producer

Сорилт:Aggregate producer sought todiversify product linebyprocessing purchasedsteel slaginsteadof naturalgranite,but was concernedabout equipment durabilityand product consistency.Solution:A midcapacity Sustainable Slag Crusher Plantwith Hardoxlined componentsand precise hydraulic adjustmentfor final gradingwas supplied.Үр дүн: The plant produceshighqualityslagaggregate meeting local road base specifications.Wear part life matchedthat oftheircurrent granitecrushers,doubling initial projections.Product consistencyallowed themtosecure alongterm supply contractwith areadymix concrete company,increasing overall site profitabilityby18%.

7.АРИЛЖААНЫ ХЭРЭГЛЭЭ

Equipment pricing is structured around capacityand configuration complexity:

• Base Tier(50100Цагдаа): Includes corecrushing circuit,basic magnetic separation,and dust control.Ideal forsiteswith lower volumeor pilot projects.• Гүйцэтгэлийн түвшин(150300Цагдаа): Most common configuration.Includes all core featureslisted above(highstrength rotors,twostage magnets,vibration monitoring).Suitable formoststeel plantsand dedicated processors.• HighCapacity Tier(400+Цагдаа): Fully automatedplantswith advanced control systems,belt scales,and expanded modularity.For largescale operationsrequiring maximum uptime.

Нэмэлт шинж чанарууд:
• Automated Metal Detection& Tramp Removal System• Advanced Process Control(APC)Software Package• Onboard Power Generation Package• ExtendedWear Part Warranty Packages

Үйлчилгээ& Санхүүжилт:
• Comprehensive service packagesare available,rangingfrom annual inspectionsto fullsite operation& maintenance contracts.• Financing optionsinclude equipment leasing,tailored rentaltoown agreements,and project financing supportthrough partner institutions.

8.Түгээмэл асуултууд

Q1:What typesof slagsis this plant most effectivefor?
A1:The plantis engineered specificallyforthe highabrasion characteristicsof aircooled Blast Furnace(BF)slagand basic oxygen furnace(BOF)/electric arc furnace(EAF)steel slags.It can also process some nonferrous slags,but we recommend aconsultationtoreview specificmaterial propertiesfirst.

Q2:Canyourplant be integratedinto our existingmaterial handlingflow?
A2 Yes.Modular design allows usto interfacewith your currentfeed systems(дамжуулагч,truck dump hoppers)and dischargeinto existing screeningor stockpiling lines.Control system integrationis standard practice

Q3:Whatisthe expected operational costperton processed?
A3 Cost perton variesbasedon local power rates,хөдөлмөр,and feed characteristics.Field datafrom similar installationsshows operational costs(excluding labor)typically rangingbetween$0 .85$1 .25perton when factoringpower,wears parts,болон урсгал засвар үйлчилгээ

Q4 Howlongdoesinstallation typically take?
A4 Foraskidmounted modularplant onsite installation,cabling,and commissioningtypically requires4–6weeks following deliveryof all modules.This significantly reducesdisruptioncomparedtoconventional foundationbased builds

Q5 Whatkindoftrainingis providedforour operators?
A5 We provide comprehensiveonsite trainingcovering safe operation,байнгын засвар үйлчилгээний журам,troubleshooting basics,and control system use.Training documentationincludes detailed manualsand video resources

Q6 Are spare parts readily availableglobally?
A6 We maintainacentralized global inventoryof critical wear parts.Common consumable itemslike liner platesare stockedregionallyto ensure lead timesof under72hours formost customers

Q7 Do youofferperformance guarantees?
A7 Yes.We provideguaranteeson minimum throughputcapacityunder defined feed conditions,wears part life expectancybasedon agreed material analysis,and metallic recovery ratesThese are detailed inthe commercial proposal