1. PEMBUKAAN PAINPOINT DRIVEN

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. GAMBARAN KESELURUHAN PRODUK

A Loji Penghancur sanga is a stationary or semimobile processing system engineered specifically for the size reduction of aircooled blast furnace (BF) sanga atau sanga keluli. Its core function is to crush large slag lumps into precisely graded aggregates for use in construction, Bangunan Jalan, or as a feedstock for further metal recovery processes.

Aliran Kerja Operasi:
1. Suapan & PraSkrining: Slag is loaded via excavator or loader into a robust feed hopper, often with a grizzly section to bypass fine material.
2. Penghancuran utama: A heavyduty jaw crusher or impact breaker reduces large lumps (often up to 1m+) kepada saiz yang boleh dikawal.
3. Pemindahan & Menghancurkan sekunder: Bahan dihantar ke penghancur sekunder (typically a cone crusher or impact crusher) for further refinement to the target product size.
4. Saiz & Perpisahan: Crushed material passes through vibrating screens to separate it into specified fractions (mis., 05mm, 510mm, 1020mm). Magnetic separators are often integrated at this stage to extract remaining ferrous metal.
5. Stok: Agregat yang digredkan dihantar ke stok simpanan yang ditetapkan untuk dihantar.

Skop Permohonan: Ideal untuk loji keluli bersepadu, kawasan pemprosesan sanga sendiri, dan pengeluar agregat yang mengkhusus dalam produk sampingan perindustrian.
Batasan: 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. CIRI TERAS

Konfigurasi Penghancur Tugas Berat | Asas Teknikal: Manganese steel jaws/liners with optimized crushing chamber geometry | Faedah Operasi: Sustained high throughput of highly abrasive material with reduced risk of premature failure | Kesan ROI: Lower costperton crushed via extended wear life and reduced frequency of liner changes.
Sistem Pemulihan Logam Bersepadu | Asas Teknikal: Overband magnetic separators positioned at key discharge points | Faedah Operasi: Berterusan, automated extraction of residual ferrous metal from the aggregate stream | Kesan ROI: Creates an additional revenue stream from recovered scrap metal while protecting downstream equipment from tramp metal damage.
Vibration Dampening Base Frame | Asas Teknikal: Reinforced steel frame with antivibration mounts for major components | Faedah Operasi: Minimizes structural stress and transmitted vibration, ensuring stable operation and reducing foundation requirements | Kesan ROI: Lowers installation complexity and cost, enhances longterm structural integrity of the plant.
Centralized Greasing & Mata Pemantauan | Asas Teknikal: Manifolded lubrication lines for all major bearing points | Faedah Operasi: Membolehkan selamat, efficient routine maintenance without requiring access to multiple isolated points during operation | Kesan ROI: Reduces lubrication time by up to 50%, promotes bearing health, and decreases unscheduled downtime.
Adjustable Discharge Setting System | Asas Teknikal: Hydraulic or mechanical adjustment on secondary/tertiary crushers | Faedah Operasi: Allows operators to quickly change final product sizing to meet different market specifications | Kesan ROI: Enables rapid response to changing customer demands, maximizing plant utilization and sales opportunities.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Industry Standard Slag Processing | Penyelesaian Loji Penghancur Sanga Kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Jumlah Tanam (Bahan Pelelas)| Pembolehubah, often declines with liner wear| Consistent output maintained via optimized wear part design & flow| Hingga 1520% more consistent yield over liner life |
| Kecekapan Pemulihan Logam| Singlestage magnetic separation, often manual cleaning| Multistage magnetic separation at optimal transfer points| Ferrous recovery rates improved by 2530% |
| Masa Henti Penyelenggaraan (Dijadualkan)| Dispersed lube points; manual setting adjustment| Centralized systems & hydraulic adjustment features| Routine service time reduced by approximately 40% |
| Ketekalan Bentuk Produk| 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. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 50 TPH berakhir 300 Tph, depending on feed size and required product grading.
Keperluan kuasa: Jumlah kuasa terpasang biasanya berkisar dari 150 kW kepada 600 kw, supplied by mains connection or onboard diesel generator set for semimobile units.
Spesifikasi Bahan: Primary wear components (pelapik, impeller bars) manufactured from highchrome martensitic steel or premium manganese steel. Structural frames use heavyduty rolled steel sections.
Dimensi Fizikal (Persediaan Biasa): Footprint varies by capacity; a 150 TPH plant may require approximately 25m (L) x 18m (W) x 12m (H).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C. Dust suppression systems are standard to maintain environmental compliance.

6. SENARIO APLIKASI

Laman Sanga Loji Keluli Bersepadu | Cabaran: Inefficient primary breaking causing backlog; low recovery of valuable metallics from old slag dumps leading to lost revenue. | Penyelesaian: Deployment of a turnkey Slag Crusher Plant with highcapacity jaw crusher for primary reduction and two stages of magnetic separation. | Keputusan: Processing rate increased to 180 Tph; 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 | Cabaran: Existing plant struggled with extreme abrasiveness of steel slag, resulting in unsustainably high wear part costs and poor product shape limiting marketability.| Penyelesaian: Installation of a purposebuilt Slag Crusher Plant featuring specialized abrasionresistant liners and a cone crusher secondary stage for improved particle shape.| Keputusan: Wear part lifecycle extended by over 60%; produced highquality cubical aggregate meeting road base specifications; opened access to highervalue construction contracts.

7. PERTIMBANGAN KOMERSIL

Loji Penghancur Slag kami ditawarkan dalam tiga peringkat utama:
Konfigurasi Standard: A robust base plant covering primary crushing, basic screening/conveying, and singlestage magnetic separation.
Konfigurasi Pemulihan Dipertingkat: 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, pakej penjanaan kuasa atas kapal, and custom conveyor lengths.

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

8. Soalan Lazim

1. Is your Slag Crusher Plant compatible with our existing conveyors and screening equipment?
ya; 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. Apakah terma komersial standard yang ditawarkan?
We typically offer FOB pricing exworks alongside CIF quotations for international buyers; payment terms are structured around project milestones such as FAT (Ujian Penerimaan Kilang).

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