1. PEMBUKAAN PAINPOINT DRIVEN

Menguruskan sanga adalah kesesakan yang berterusan dengan kos yang ketara. Adakah anda menghadapi cabaran operasi ini?
Throughput Tidak Boleh Dipercayai: Inconsistent crusher performance creates pileup at the furnace or converter, delaying tapping schedules and disrupting upstream production.
Excessive Downtime: Kegagalan mekanikal yang kerap, particularly from uncrushable tramp metal or abrasive materials, lead to unscheduled maintenance, kos penggantian alat ganti yang tinggi, and lost processing hours.
Kos Operasi yang Tinggi: Haus pramatang pada tukul, pelapik, and rotors from highimpact crushing drives a continuous cycle of consumable expenditure and labor for changes.
Keselamatan & Bahaya Pengemasan: Dust generation during crushing and the handling of jagged, oversized slag fragments pose risks to personnel and create a problematic worksite environment.
Inflexible Output: Inability to adjust final product size efficiently limits your ability to meet specific grading requirements for different recycling or aggregate applications.

Soalan teras untuk pengurus loji ialah: how can you transform slag from a costly byproduct into a reliable, revenuegenerating stream without compromising primary production?

2. GAMBARAN KESELURUHAN PRODUK: ODM SLAG CRUSHER PLANT

An ODM (Pengeluar Reka Bentuk Asal) Slag Crusher Plant is a customengineered, stationary or semimobile processing system designed specifically for the reduction of metallurgical slag. Unlike standard offtheshelf crushers, an ODM plant is fabricated based on your specific slag analysis, kapasiti yang diperlukan, dan kekangan tapak.

Aliran Kerja Operasi:
1. Suapan & PraSkrining: Slag from the ladle or stockpile is fed via apron feeder or conveyor. An initial grizzly section removes fine material bypassing the crusher.
2. Pengurangan saiz utama: Penghancur teras (typically a robust impactor or jaw crusher) accepts large chunks (sehingga 1m+) and reduces them to a manageable size (mis., <200mm).
3. Tramp Metal Separation: A critical stage where an overhead magnetic separator removes ferrous tramp metal after primary crushing but before menghancurkan sekunder, melindungi peralatan hiliran.
4. Menghancurkan sekunder & Pemeriksaan: A secondary crusher (often a cone or impactor) further reduces material, which is then screened into specified product fractions (mis., 010mm, 1040mm).
5. Stok & Penghantaran: Sized products are conveyed to designated stockpiles for loading out.

Skop Permohonan & Batasan:
Skop: Ideal untuk loji keluli bersepadu, pelebur tembaga/nikel, and ferrous alloy producers processing aircooled blast furnace (BF) Slag, sanga relau keluli (BOF/EAF), and nonferrous slags with manageable metal content.
Batasan: Tidak direka untuk pengendalian sanga cair. Performance is contingent on accurate feed material analysis; slags with extremely high metallic yield or tenacious composite materials may require pretreatment or specific crusher configurations.

3. CIRI TERAS

Pemasangan Rotor Tugas Berat | Asas Teknikal: Forged steel rotor discs with highinertia design | Faedah Operasi: Sustains higher kinetic energy for effective breakage of dense slag lumps with less wear per ton processed | Kesan ROI: Reduced specific power consumption (kWj/tan) and longer intervals between rotor service.

Pelarasan Hidraulik & Perlindungan beban | Asas Teknikal: Integrated hydraulic cylinders for setting adjustment and automatic release upon uncrushable object entry | Faedah Operasi: Operators can adjust product size settings quickly under load; system protects itself from severe damage by tramp metal | Kesan ROI: Minimizes risk of catastrophic failure events that cause days of downtime.

Sistem Pelapik Tahan Lelasan | Asas Teknikal: Bolton liner plates manufactured from proprietary AR steel alloys (400500+ Brinell) in optimized wear zones | Faedah Operasi: Liners withstand extreme abrasion from crystalline slag structure, extending service life in highwear areas like impact aprons and breaker plates | Kesan ROI: Lowers total cost of ownership through fewer liner changeouts and associated labor.

Enclosed Housing with Dust Extraction Ports | Asas Teknikal: Sealed crusher housing engineered with strategically placed flanges for connection to plant dust suppression or collection systems | Faedah Operasi: Significantly contains dust generated at primary impact points, meningkatkan keterlihatan tapak dan kualiti udara | Kesan ROI: Reduces housekeeping costs and supports compliance with workplace environmental standards.

Laluan Modular & Maintenance Access | Asas Teknikal: Integrated platforms, tangga, and pullout sections designed around major service points (pemutar, pelapik) per maintenance procedure study | Faedah Operasi: Technicians perform routine inspections, Perubahan pelapik, and major overhauls safely and efficiently with correct tool access | Kesan ROI: Mengurangkan masa henti penyelenggaraan yang dirancang sehingga 30% based on field data comparisons.

Centralized Greasing & Titik Pemantauan Keadaan | Asas Teknikal: Manifolded lubrication lines routing from central stations to all key bearings; provision for sensor (getaran,suhu) pemasangan | Operational Benefit Ensures consistent bearing lubrication critical in highshock environments; enables predictive maintenance protocols| ROI Impact Prevents bearing seizure failures extends component life reduces unplanned stoppages

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penyelesaian Standard Industri | ODM Slag Crusher Plant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Adanya (%)| 8085% (downtime for wear changes/breakdowns)| 9295% (designformaintenance access + sistem perlindungan)| +10% operasi operasi |
| Peringkat Utama Kehidupan Pelapik (Jam)| ~500600 hrs on abrasive BF slag| ~750900 hrs via optimized alloy/design| +40% pakai nyawa |
| Peristiwa Kerosakan Tramp Metal| 23 significant incidents/year average| 80% reduction in related repairs |
| Penggunaan Tenaga Khusus| Benchmark varies; typically higher due to inefficient reduction| Lower kWh/ton via highinertia rotor & optimal chamber geometry| Data lapangan menunjukkan 812% penambahbaikan |
| Ketekalan Throughput (±%)| +/ 15% variance due to bridging/wear performance decay|< +/ 5% variance via controlled feed & adaptive crushing action| More predictable downstream process flow |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 150 TPH berakhir 600 Tph, based on feed characteristics and required product sizing.
Keperluan kuasa: Pemacu penghancur utama biasanya berkisar dari 250 kW kepada 500 kw, dependent on model capacity; total plant connected load includes conveyors, skrin,and auxiliaries.
Spesifikasi Bahan:
Crusher housing/frame: Heavyduty structural steel plate (>25mm in stress areas).
Wear components: Manganese steel or chromium carbide overlays for hammers/impactor bars; AR plate liners (>400 BHN).
Rotor shaft material: Penempaan keluli aloi (mis., 34CrNiMo6), diuji secara ultrasonik.
Dimensi Fizikal: Footprint is projectspecific; a typical primary/secondary skidmounted module may measure approximately (L)20m x (W)8m x (H)7m.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C, with optional features for dust sealing (IP65 on bearings)and highhumidity environments common in mill settings.

6. SENARIO APLIKASI

Integrated Steel Plant Blast Furnace Slag Processing

Cabaran: A major steel producer faced frequent plugging and accelerated wear in their existing hammer mill circuit when processing coarse blast furnace slag containing occasional skulls.The resulting downtime was delaying hot slag pit clearing.
Penyelesaian: Implementation of an ODM Slag Crusher Plant featuring a deepchamber primary jaw crusher followed by an overhead magnetic separatorand secondary horizontal shaft impactor.The jaw's linear compression action effectively broke the tough skulls without stalling
Keputusan: Daya tampung stabil pada 400 TPH.Plant availability increased from ~78%to93%.Wear costs on primary stage reduced by60%due to the jaw's more abrasionresistant plate design

Copper Smelter Recycling Converter Slag

Cabaran: The client neededto liberateand recover entrained copper mattefrom lump converter slag while producinga consistentminus50mm aggregatefor construction sales Existing equipment struggledwith varying feed hardnessand caused excessive fines generation
Penyelesaian: A twostage ODM plant was configuredwitha primary impactcrusheroperatingin closed circuitwitha screen This allowedfor controlledimpactbreakingfor bettermetalliberationand recirculationof oversize
Keputusan: Matte liberation efficiency improved allowingfor highermetal recovery ratesin downstreamprocessing Aggregateproduct cubicity met premiumspecifications enablinga20%increasein salesprice Fines generationwas reducedby15%

7.PERTIMBANGAN KOMERSIL

ODM Slag Crusher Plants are capital investments priced accordingto capacity complexityand material specifications

Peringkat Harga
– Base Configuration Skidmountedprimarycrushingmodulewith basic discharge conveyor Starting point formajor projects
– StandardizedPlant Includesprimarycrusher magnetic separator secondarycrusherscreen moduleand controlpanel The most commonturnkeysolution
– Fully CustomizedSystem Engineeredfor complexlayouts multipleproductsizes automatedmaterialhandlingandsophisticatedcontrols

Optional Features include advanced condition monitoring systems automated grease systems speciallinermaterials forextreme abrasion dust suppression cannon integrationand sound attenuation enclosures

Service Packages typicallycompriseawarrantyperiod followedby annualmaintenancecontracts offering scheduledinspections priorityparts supplyand experttechnical support Financing options suchas equipment leasingor project financingare often availablethroughpartner institutions tomatchcapitalexpendituretothe asset'sproduction lifecycle

Soalan Lazim

Q1 Is an ODM plant compatible with our existing material handling system?
A Yes A core principleofODM fabricationis interfaceengineering We designfeedand discharge points conveyor heightsand control integrationtomatchyour currentlayout minimizingcivilwork

Q2 What data do you needto providefor an accurate proposal?
A Criticaldata includeslag sampleanalysis(chemicalcomposition hardnessabrasiveness) requiredhourlyannual tonnage incomingfeed sizemaximum lump size desiredfinalproductsizesand any siterestrictions

Q3 How does this solutionimpact our ongoing operational manning?
A The plantsaredesignedfor semiautomaticoperationfromacontrolroom Typically oneoperatorcan manage thecrushing circuit reducing directlabor comparedto multiplemobileunits Howevermaintenanceplanningrequirements remain

Q4 Whatisthetypical deliveryandlead timefrom orderto commissioning?
A For standardizedplants lead timesrangebetween26and36weeks dependingon component sourcing Custom designsrequire additional engineeringtime Lead timeis definedafter finalprocess designcriteriaare approved

S5 Adakah jaminan prestasi ditawarkan?
A Yes contractsinclude guaranteedcapacity basedon agreed feedmaterial specifications as wellas guaranteed maximum power consumption Product sizing guaranteescan alsobe providedforspecific configurations

Q6 How are spare parts managed longterm?
A We maintaindetailed billofmaterialsforall fabricatedplants Criticalspare partkits arerecommendedat purchase Comprehensive drawingsandsupplychain informationare providedtothe client ensuringpartstraceabilityfor decades

Q7 Can the plant handle variationsinslag composition between differentfurnacesor campaigns?
A The robustdesignaccommodatesnormalvariability Featureslike hydraulic adjustmentallowoperatorsto compensate For majorschangesin materialcharacteristics(eg switchingfromBFtoEAFslag)a processreviewis recommended