1. PEMBUKAAN PAINPOINT DRIVEN

Managing slag is a persistent, highcost operational bottleneck. Adakah anda menghadapi cabaran khusus ini?
Kos Pelupusan Tinggi & Liabiliti: Landfill fees and environmental compliance for untreated slag are escalating annually, directly eroding project margins.
Inefficient Material Handling: Manual breaking or inconsistent crushing of slag leads to low throughput, creating stockpile congestion and delaying site clearance.
Premature Downstream Wear: Uncrushed or irregularly sized slag with metallic inclusions causes excessive abrasion and damage to conveyor belts, skrin, and secondary crushers.
Lost Revenue Streams: Valuable metallic content remains trapped within the slag, and inconsistent aggregate size prevents its profitable sale for secondary applications like road base or cement additives.
Unscheduled Maintenance Stops: Equipment not engineered for the abrasive, highimpact nature of slag suffers frequent breakdowns, resulting in unplanned downtime and repair costs.

Persoalan utama untuk pengurus loji ialah: how do you transform this problematic byproduct from a cost center into a controlled, revenuegenerating process? The answer lies in selecting a purposebuilt China Slag Crusher Plant.

2. GAMBARAN KESELURUHAN PRODUK

A China Slag Crusher Plant is a stationary or semimobile crushing circuit specifically engineered to process metallurgical slag (relau letupan, relau keluli). It is designed to withstand extreme abrasion and intermittent shock loads from uncrushable metallic remnants.

Aliran Kerja Operasi:
1. Pengurangan saiz utama: Large slag chunks (up to 1m+) dimasukkan ke dalam penghancur utama yang mantap (typically a jaw crusher or impact crusher) for initial breaking.
2. Pemisahan Logam & Scrap Recovery: Crushed material passes over an overhead magnetic separator to extract ferrous scrap for recycling, melindungi peralatan hiliran.
3. Menghancurkan sekunder & Membentuk: Material is conveyed to a secondary crusher (often a cone crusher or impactor) to achieve the desired final aggregate size and shape.
4. Saiz & Stok: Screens classify the crushed slag into specified fractions (mis., 05mm, 520mm), which are then conveyed to designated stockpiles for sale or further processing.

Skop Permohonan & Batasan:
Skop: Ideal untuk kilang keluli bersepadu, faundri, peleburan, and dedicated slag processing yards handling ferrous and nonferrous slags.
Batasan: Not suitable for primary ore processing where feed material differs significantly in hardness and composition. Plant configuration must be matched to feed size analysis and required final product specifications.

3. CIRI TERAS

Rotor Tugas Berat & Impact Plates | Asas Teknikal: Highchromium alloy castings with optimal weighttoinertia ratio | Faedah Operasi: Sustains impact energy transfer through abrasive cycles; reversible plates extend wear life by up to 40% | Kesan ROI: Reduces consumable parts cost per ton and increases mean time between maintenance intervals.

Integrated Magnetic Separation System | Asas Teknikal: Selfcleaning crossbelt magnet installed postprimary crushing | Faedah Operasi: Automatically removes tramp metal before secondary crushing stage | Kesan ROI: Prevents catastrophic damage to downstream crushers and conveyors; recovers valuable scrap metal.

Pelarasan Hidraulik & Membersihkan | Asas Teknikal: PLCcontrolled hydraulic cylinders for gap setting and overload release | Faedah Operasi: Allows operators to adjust product size onthefly and automatically clear blockages in minutes | Kesan ROI: Minimizes downtime from chamber jams; enables quick adaptation to changing product requirements.

Bingkai Bertetulang & Bearing housings | Asas Teknikal: Analisis Unsur Terhingga (FEA)optimized steel fabrications with oversized bearing assemblies | Faedah Operasi: Absorbs high dynamic loads from uneven slag feed and uncrushables without structural fatigue | Kesan ROI: Ensures longterm structural integrity, preventing costly frame cracks or bearing failures.

Centralized Greasing & Titik Pemantauan Keadaan | Asas Teknikal: Manifolded lubrication lines with diagnostic ports at key wear points | Faedah Operasi: Membolehkan selamat, efficient routine maintenance and allows for periodic vibration/ temperature analysis | Kesan ROI: Facilitates predictive maintenance scheduling, preventing unexpected stoppages.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Generic Aggregate Plant) | China Slag Crusher Plant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Wear Part Life in Slag Duty | Manganese Steel Hammers/Concaves | Aloi HighChrome & Composite Ceramic Inserts | +6080% |
| Metal Contamination Removal| Manual picking or postcrushing separation| Inline magnetic separation at transfer points| +95% metal recovery; eliminates downstream damage |
| Availability for Abrasive Feed| ~7580% due to frequent wear changes| ~9295% with designed wear resistance & quickchange systems| +1520% masa beroperasi |
| Total Cost per Ton Processed| Higher consumable cost + risk of major damage| Predictable wear cost + scrap revenue offset| Data lapangan menunjukkan 2535% lower net processing cost |

5. SPESIFIKASI TEKNIKAL

Kapasiti Pemprosesan: Boleh dikonfigurasikan daripada 50 TPH berakhir 500 Tph.
Saiz suapan: Accepts runofslag up to 1000mm x 800mm.
Final Product Size: Adjustable output ranges from 040mm.
Keperluan kuasa: Primary plant motor power from 160kW to 400kW+; total installed power dependent on configuration (penghantar, skrin).
Spesifikasi Bahan Utama:
Crusher liners/impact plates: Cr26/Cr27 highchromium iron.
Feed chute liners: AR400 abrasionresistant steel plate.
Conveyor skirting & pakai pelapik: Replaceable ceramic/urethane composite.
Dimensi Fizikal (Typical SkidMounted Module): L~20m x W~6m x H~5m (varies significantly with layout).
Julat Operasi Persekitaran: Direka untuk suhu ambien 20°C hingga +45°C; dust suppression system compliant with local particulate emission standards.

6. SENARIO APLIKASI

Cabaran Kompleks Keluli Bersepadu:

A major mill faced escalating landfill costs for its blast furnace slag and needed reliable aggregate for internal road maintenance. Their existing equipment suffered constant liner wear and belt damage from hidden "tramp iron."

Penyelesaian:

Implementation of a turnkey China Slag Crusher Plant featuring an impact crusher with integrated magnet and multiple product screening stations.

Keputusan:

Achieved consistent production of three graded aggregates. Landfill costs reduced by 100%; internal road material costs eliminated. Metallic recovery generated incremental revenue. Payback period achieved in under 18 bulan.

Independent Slag Processing Yard Challenge:

A contractor processing purchased slag piles required higher throughput flexibility but struggled with unpredictable feed composition causing frequent plant blockages and unplanned labor for metal removal.

Penyelesaian:

Installation of a modular jaw crusher plant as primary stage with heavyduty grizzly feeder followed by secondary cone crushers configured specifically for variableslag duty.

Keputusan:

Throughput increased by over 30%. Blockages reduced by over 90% due to effective primary scalping and metal removal. The plant's adjustability allowed processing of different client slags without major reconfiguration.

7. PERTIMBANGAN KOMERSIL

Peringkat Harga: Investment varies based on capacity and automation level.
Konfigurasi Standard: Termasuk modul penghancuran teras, basic conveyors, magnet separator, starter motors—optimal for straightforward volume reduction goals.
Konfigurasi Dipertingkat: Adds multistage screening decks, automated dust suppression PLC control systems—suited for producing multiple specification products simultaneously.
Turnkey Project: Covers full civil works foundation design), installation commissioning supervision extended training—providing complete operational readiness
Ciri Pilihan: Advanced condition monitoring sensors remote diagnostics telemetry water spray systems noise enclosures
Service Packages range from annual inspection plans comprehensive spare parts holding agreements onsite technical support contracts
Financing Options available through manufacturer partnerships include equipment leasing mediumterm loans progressbased payment plans tailored largescale projects

8 Soalan Lazim

What types of slags can this plant process?
These plants are primarily engineered ferrous slags blast furnace BOF EAF Nonferrous slags copper nickel require specific material analysis liner selection due differing abrasiveness chemical properties

How does the plant handle uncrushable metal pieces that bypass the magnet?
The core crushers incorporate hydraulic overload protection systems automatically release open chamber discharge tramp item without causing shaft damage Operators can then remove object

What typical installation timeline civil works required?
For skidmounted modular plant minimal foundation work required Installation commissioning typically completed within weeks following delivery Site requires prepared level base adequate access craneage

Can existing conveyors other equipment integrated into new slag crushing plant?
Yes engineering assessments conducted ensure compatibility feed rates heights load Existing equipment often incorporated especially downstream screening stockpiling sections control system integration provided

What key metrics used calculate ROI specific operation?
Critical factors include current disposal fees per ton value recovered scrap metal target price sold aggregate reduced maintenance costs existing equipment increased throughput Analysis based your local figures

Are operating consumables readily available internationally?
Major manufacturers maintain standardized wear part inventories global distribution networks ensure lead times critical components like liners blow bars kept minimum often under weeks

What aftersales support typically included purchase?
Standard offering includes detailed operational maintenance manuals remote support Factorytrained technicians available commissioning Most suppliers offer firstyear warranty manufacturing defects critical components