1. PEMBUKAAN PAINPOINT DRIVEN

Managing slag is a persistent, costly operational bottleneck. Adakah anda menghadapi cabaran ini?
High Downtime for Primary Crusher Maintenance: Frequent liner changes and unplanned breakdowns in your primary crushing circuit halt downstream processing, menelan belanja beribu-ribu sejam dalam pengeluaran yang hilang.
Kos Bahagian Haus Berlebihan: The abrasive, often unpredictable nature of slag rapidly degrades standard crusher components, leading to unsustainable consumable expenses and frequent maintenance windows.
Inefficient Liberation of Valuable Metals: Incomplete crushing leaves encapsulated metals within slag aggregates, resulting in direct revenue loss from unrecovered materials and diminished product purity.
Saiz Suapan Tidak Konsisten & Throughput: Fluctuations in slag feed size and hardness cause chokefeeding or cavitation, preventing your plant from achieving stable, designed capacity.
Beroperasi Tinggi & Safety Overheads: Manual breaking, frequent maintenance interventions, and dust generation increase labor costs and expose personnel to unnecessary risk.

Is your current solution equipped to handle the specific abrasiveness and density of slag while maximizing metal recovery and minimizing total cost of ownership?

2. GAMBARAN KESELURUHAN PRODUK: LUXURY SLAG CRUSHER PLANT

The Luxury Slag Crusher Plant is a heavyduty, stationary or semimobile crushing system engineered specifically for the primary and secondary reduction of ferrous and nonferrous slags. Ia berubah menjadi besar, irregular slag feed (sehingga 1.5m) into a precisely calibrated aggregate for further processing or sale.

Aliran Kerja Operasi:
1. Penghancuran utama: Dumpfed slag is reduced by a robust jaw crusher or gyratory crusher designed for extreme abrasion.
2. PraSkrining & Metal Recovery: Initial screening separates fines; magnetic separation extracts liberated ferrous metals at the earliest stage.
3. Menghancurkan sekunder & Membentuk: A cone crusher or impact crusher with specialized liners performs tertiary reduction for optimal particle shape.
4. Saringan Akhir & Pengelasan: Multideck screens sort output into commercial aggregate fractions (mis., 05mm, 520mm, 2040mm).
5. Penindasan Debu & Kawalan: Integrated spray systems maintain dust levels well below regulatory thresholds throughout the process.

Skop Permohonan: Designed for integrated steel mills, peleburan tembaga, metal recycling facilities, and standalone slag processing contractors handling blast furnace (BFS) or steelmaking slags (EAF/LD).

Batasan: Not suitable for primary crushing of virgin rock in hightonnage mining applications where slagspecific metallurgy is not required.

3. CIRI TERAS

Rotor Tugas Berat & Reka Bentuk Dewan | Asas Teknikal: High inertia kinematics with wearprotected impact plates | Faedah Operasi: Sustains high throughput on dense (>2.8 t/m³) slag with minimal velocity loss | Kesan ROI: Hingga 15% higher consistent throughput versus standard designs reduces processing time per ton.

Liner Metallurgy Package | Asas Teknikal: Ceramicimbedded chromium carbide overlays on critical wear zones | Faedah Operasi: Increases wear life by 34x in highly abrasive silicate matrix environments | Kesan ROI: Reduces liner change frequency by over 60%, cutting parts inventory cost and maintenance labor.

Intelligent Tramp Metal Protection | Asas Teknikal: Hydraulic or pneumatic release system with autoreset functionality | Faedah Operasi: Prevents catastrophic damage from uncrushable metals (mis., besi gelandangan) tanpa menghentikan penghancur | Kesan ROI: Eliminates costly rotor repair/replacement events and associated production losses exceeding $50k per incident.

Adaptive Crushing Logic (ACL) | Asas Teknikal: PLCcontrolled variable drive adjusts closedside setting (CSS) based on realtime power draw | Faedah Operasi: Maintains optimal product gradation despite variations in feed hardness and slab size | Kesan ROI: Improves yield of highvalue aggregate fractions by an average of 12%, enhancing product revenue.

Integrated Dust Containment Skirting | Asas Teknikal: Multistage sealing at transfer points with negative pressure zones | Faedah Operasi: Contains airborne particulate at source, maintaining plant cleanliness and operator safety | Kesan ROI: Reduces housekeeping labor by an estimated 30% and ensures continuous compliance with environmental standards.

Platform Penyelenggaraan Modular | Asas Teknikal: Engineered access platforms integrated into the plant superstructure | Faedah Operasi: Menyediakan selamat, toolready access to all service points (pelapik, skrin, tali pinggang) for faster maintenance | Kesan ROI: Mengurangkan masa henti penyelenggaraan berjadual sehingga 40%, peningkatan waktu operasi tahunan.

Centralized Greasing & Sistem Pemantauan| Asas Teknikal: Automated lubricant delivery to all major bearings with flow sensors| Faedah Operasi: Ensures optimal bearing life under highload conditions and provides early failure warning| ROI Impact extends major bearing service intervals by ~25% prevents unplanned stoppages from lubrication failures

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Luxury Slag Crusher Plant Solution | Kelebihan (% Penambahbaikan) |
|||||
| Kehidupan Pakai Pelapik (Abrasive Slag) | ~600 waktu operasi | ~2,200 operating hours | +267% |
| Kecekapan Pembebasan Logam | ~8590% recovery postcrushing | ~9497% recovery postcrushing | +8% |
| Penggunaan Kuasa Khusus | ~0.9 1.1 kWj/tan | ~0.75 0.85 kWj/tan |18% |
| Masa Min Antara Kegagalan (MTBF) | ~450 jam |>720 jam |>+60% |
| Average Throughput Consistency ±15% from rated capacity ±5% from rated capacity |10pp variance |
| Pelepasan Habuk di Titik Pemindahan >10 mg/m³ <5 mg/m³ |50%

5.SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 150 ke 600 tan sejam.
Saiz Suapan Maksimum: Hingga 1500 mm panjang tepi.
Saiz Produk Akhir: Adjustable from 05mm up to 040mm.
Primary Drive Power: daripada 160 kW kepada 400 kW bergantung pada konfigurasi.
Crusher Frame Construction: Welded steel plate with reinforced stress zones; minimum yield strength of 355 MPa.
Wear Part Specifications: Primary breaker plates manufactured from Xwin® or equivalent ceramic composite material.
Jejak Fizikal (tipikal): Approximately Length=25m x Width=12m x Height=9m for a full circuit plant.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C dengan pakej pemanasan/penyejukan pilihan tersedia.

6 SENARIO APLIKASI

Integrated Steel Mill – Blast Furnace Slag (BFS) Processing Challenge:

A major mill faced escalating landfill costs for BFS and needed to produce a highquality aggregate for cement substitution but struggled with rapid wear in their existing crushers causing unreliable supply contracts

Penyelesaian:

Implementation of a turnkey Luxury Slag Crusher Plant configured with primary jaw crusher ceramic liners ACL system

Keputusan:

Achieved consistent production of SCMgrade aggregate Wear part costs reduced by $140k annually Secured a longterm offtake agreement based on reliable supply eliminating $80k/year in landfill fees

Copper Smelter – Recovering Residual Copper

Cabaran:
A smelter’s legacy process failed to liberate fine copper trapped within granulated slag leading to an estimated $2M+ annual value loss in unrecovered metal alongside lowvalue aggregate

Penyelesaian:

Installation of a secondary/tertiary Luxury Slag Crusher Plant circuit featuring highreduction cone crushers precise screening enhanced magnetic separation

Keputusan:

Copper recovery efficiency increased from %87 %96 Aggregate product value increased due cleaner mineral liberation Payback period on capital investment achieved in under months

7 PERTIMBANGAN KOMERSIL

Pricing tiers are projectspecific based on required capacity modularity level
Peringkat Tumbuhan Asas ( tph): Includes core crushing screening basic dust control
Premium Plant Tier ( tph): Adds ACL intelligent metal protection automated lubrication advanced dust suppression
Elite Turnkey Tier ( tph): Full plant design permitting modular erection commissioning training

Ciri Pilihan:
Hot Slag Handling Packages
Advanced Air Classification Systems
OnBoard Weighing Analytics
Remote Monitoring Diagnostics Portal

Pakej Perkhidmatan:
Sokongan Platinum:hour onsite response guaranteed parts availability annual health audits
Sokongan Emas:hour remote support scheduled inspections parts discount
Bronze Support: Basic preventive maintenance schedule parts supply

Financing Options available include capital lease operating lease project financing terms tailored year cycles

8 Soalan Lazim

What if our slag composition varies significantly between batches?
The Adaptive Crushing Logic automatically compensates for hardness variations maintaining product consistency without manual intervention Field data shows gradation stability improves by over compared fixedsetting systems

How does this plant integrate with our existing material handling system?
Our engineering team conducts dimensional interface analysis All plants feature standardized discharge heights conveyor widths Electrical control systems are designed for integration into your existing PLC SCADA network

What is the expected operational availability?
Based on field performance data across installations designed operational availability exceeds when following prescribed maintenance protocols This factors in scheduled downtime liner changes

Adakah alat ganti haus tersedia?
Yes We maintain regional inventory critical wear components Furthermore our liner design utilizes longlife materials reducing change frequency Consumption rates are provided during feasibility stage accurate budgeting

Adakah anda menawarkan jaminan prestasi?
Yes We provide guaranteed minimum throughput maximum power consumption wear life rates key consumables These are contractually defined after review your specific slag analysis