1. PEMBUKAAN PAINPOINT DRIVEN

Menguruskan sanga adalah kesesakan yang berterusan dengan kos yang ketara. Adakah anda menghadapi cabaran operasi ini?
Masa Henti yang Tinggi & Kos penyelenggaraan: Frequent clogging and abrasive wear in standard crushers lead to unscheduled stops, excessive part replacement, dan kehilangan waktu pemprosesan.
Inefficient Material Liberation: Inconsistent crushing fails to fully separate metal from slag, resulting in valuable ferrous recovery left in the waste stream and lost revenue.
Had Keupayaan: An undersized or improperly configured slag crusher plant creates a backlog, stalling upstream steelmaking operations and downstream material handling.
Kos Operasi yang Tinggi: Excessive power consumption from inefficient crushing mechanisms and the laborintensive management of multiple, disparate units erode profit margins.
habuk & Pematuhan Bunyi: Uncontrolled particulate emissions and noise levels from crushing operations risk regulatory noncompliance and create unsafe workplace conditions.

Soalan untuk pengurus loji adalah jelas: how can you transform slag from a costly byproduct into a streamlined, profitable recovery operation while ensuring reliability and compliance?

2. GAMBARAN KESELURUHAN PRODUK

A modern Slag Crusher Plant is a purposebuilt, integrated processing system designed for the efficient reduction and liberation of slag from steel mills, peleburan, dan faundri. Its core function is to crush large slag lumps into finely graded aggregate, maximizing the recovery of entrapped metallic content.

Aliran Kerja Operasi:
1. Penghancuran utama: Suapan sanga besar (sehingga 1000mm) is reduced by a heavyduty jaw crusher or impactor capable of handling highabrasion material.
2. Pemisahan Magnetik: Initial recovery of liberated metallic pieces via suspended or drum magnets integrated into the conveyor system.
3. Sekunder & Penghancuran tertiari: Further size reduction via cone crushers or impactors to ensure complete metalslag liberation.
4. Pemeriksaan & Final Separation: Material is classified by vibratory screens; oversize is recirculated, while correctly sized aggregate passes under additional magnetic separators for final metal extraction.
5. Stockpiling/Transport: Cleaned slag aggregate is conveyed to stockpiles for sale or reuse; recovered metal is collected for recycling.

Skop Permohonan: Ideal untuk loji keluli bersepadu, kilang mini, peleburan tembaga, and ferrous/nonferrous foundries. Designed for blast furnace (BF) Slag, sanga relau keluli, and similar metallurgical byproducts.

Batasan: Not designed for primary ore processing or extremely hard, nonmetallic minerals. Feed size and composition must be evaluated against plant design specifications.

3. CIRI TERAS

Penghancur Rahang Tugas Berat | Asas Teknikal: Manganese steel jaws with optimized nip angle | Faedah Operasi: Mengendalikan besar, irregular slag lumps without bridging; withstands extreme abrasion | Kesan ROI: Mengurangkan masa henti peringkat utama sehingga 40%, lowering maintenance labor and parts costs.

Sistem Pemisahan Magnet Bersepadu | Asas Teknikal: Multiple stages of electro/permanent magnets at critical transfer points | Faedah Operasi: Maximizes ferrous metal recovery directly during material flow | Kesan ROI: Increases metal yield revenue by capturing an additional 515% of residual ferrous content often missed in singlestage systems.

Sistem Kawalan PLC Berpusat | Asas Teknikal: Automated process control with load monitoring and fault diagnostics | Faedah Operasi: Enables singleoperator oversight of entire crushing circuit; prevents equipment damage due to overloads | Kesan ROI: Lowers manpower requirements and eliminates costly motor/gear failures due to tramp metal or blockages.

AbrasionResistant Conveying Circuit | Asas Teknikal: Pelapik keluli AR400, katil impak, and sealedforlife bearings on conveyors | Faedah Operasi: Dramatically extends belt and component life in highwear transfer zones | Kesan ROI: Cuts annual conveyor maintenance costs by an average of 30% compared to standard systems.

Penindasan Debu & pembendungan | Asas Teknikal: Pressurized water spray nozzles at crusher inlets/vibrating screens with enclosure panels | Faedah Operasi: Effectively controls airborne particulate at source | Kesan ROI: Ensures environmental compliance avoids fines reduces housekeeping labor protects worker health.

Reka Bentuk SkidMounted Modular (Pilihan) | Asas Teknikal: Preassembled modules on structural skids| Faedah Operasi: Significantly reduces onsite civil work installation time commissioning period| ROI Impact Cuts total project installation costs by up to 25% gets your operation generating revenue weeks faster

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penyelesaian Standard Industri | Penyelesaian Loji Penghancur Sanga Kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Kadar Pemulihan Logam | Singlestage magnetic separation after primary crush. | Multistage magnetic separation before after each crushing stage.| +1218% more metal recovered |
| Kehidupan Pakai Pelapik (Utama)| Standard manganese jaws replaced every 46 bulan.| Proprietary alloy composition heat treatment.| +6080% hayat perkhidmatan yang dilanjutkan |
| Ketersediaan Masa Beroperasi Sistem| ~80%, factoring in unplanned stops for clearing cleaning.| >92%, achieved via robust design automated protection.| +15% peningkatan dalam jam produktif |
| Penggunaan Kuasa setiap Tan| Fixedspeed drives across all motors.| Configured with variable frequency drives (VFDS) on feeders conveyors.| 1015% kos tenaga yang lebih rendah |
| Pemasangan & Pentauliahan| 812 weeks field assembly wiring.| 46 weeks for skidmounted modular plants.| ~50% penggunaan lebih pantas |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 50 TPH berakhir 300 Daya pengeluaran TPH.
Saiz suapan: Menerima sanga ketulan sehingga 1000mm panjang tepi.
Saiz Produk Akhir: Adjustable output from 20mm to 50mm based on screen configuration.
Keperluan kuasa: Jumlah beban bersambung daripada 150 kW kepada 800 kW depending on plant size; supplied at 415V/50Hz or customized voltage/frequency.
Spesifikasi Bahan Utama:
Crusher Jaws/Liners: Keluli Mangan Premium / HighChrome Iron Alloy
Chassis/Skids: Heavyduty structural steel (IS 2062)
Belting Penghantar: Minimum EP400/3 with abrasionresistant top cover
Dimensi Fizikal (for typical 100 TPH skid plant): Lebih kurang. Length 25m x Width 8m x Height 6m (tidak termasuk corong suapan).
Julat Operasi Persekitaran: Designed for ambient temperatures from 10°C to +45°C dustladen environments includes provisions for dust extraction system connection

6. SENARIO APLIKASI

Integrated Steel Plant Blast Furnace Slag Processing Challenge Significant downtime on aging primary crusher causing upstream BF granulation pit overflow inconsistent product size affecting sales Solution Replacement with a turnkey Slag Crusher Plant featuring heavyduty primary impactor multistage magnetic separation automated control Results Achieved consistent throughput of120 TPH product sizing within spec increased metal recovery by15 tons per month eliminated unplanned downtime events

MiniMill Electric Arc Furnace (EAF) Slag Challenge Need for compact footprint solution limited space high dust generation creating compliance issues manual handling was laborintensive Solution Installation of a modular skidmounted Slag Crusher Plant with integrated dust suppression enclosures Results Plant operational within5 weeks of delivery dust emissions reduced below permissible exposure limits(PEL) labor requirement cut from3 shifts to1 shift oversight

Copper Smelter Slag Recovery Challenge Processing complex slag containing residual copper matte requiring careful handling achieve specific granulometry for further mineral processing Solution Customdesigned Slag Crusher Plant with specialized liner alloys slower crushing speeds minimize fines generation enhanced ventilation at transfer points Results Optimized particle size distribution increased copper concentrate grade in downstream flotation circuit improved working environment through better dust control

7 PERTIMBANGAN KOMERSIL

Loji Penghancur Slag kami ditawarkan dalam tiga peringkat utama:

1. Standard Configuration A costeffective solution covering core crushing screening basic magnetic separation ideal for welldefined consistent feed materials
2 Advanced Configuration Includes multistage VFDs advanced PLC automation highergrade wear materials recommended for maximum uptime complex feed
3 Custom Engineered Solutions Tailored layouts special material handling requirements integration with existing granulation or sorting systems

Optional Features Upgrades include:
• Metal Detectors NonFerrous Recovery Systems(Eddy Current Separators)
• Advanced Baghouse Dust Collection Systems
• Remote Monitoring IoT Data Logging Packages
• Extended Warranty Coverage Critical Components

Service Support We offer comprehensive packages:
• Annual Maintenance Contracts(AMC)with scheduled inspections parts discounts
• OnDemand Field Service Technician Support
• Wear Parts Kits ensuring optimal inventory levels

Financing Options Available through partner institutions include:
• Equipment Leasing Structures
• Term Loans
• RenttoOwn Programs

Request a detailed quotation based on your specific annual tonnage feed characteristics site layout required final product specifications

FAQ – SLAG CRUSHER PLANT SOLUTIONS

Q1 What are the key factors determining the right capacity size?
The primary factors are your daily monthly slag generation volume required final product size needed metallic recovery rate A detailed analysis of your feedstock including lump size distribution hardness metallic content ensures correct sizing

Q2 How does this plant integrate with our existing material handling system?
Our engineering team will review your current conveyor layouts feed discharge points We design transition hoppers chutes interface conveyors ensure seamless integration minimal disruption during installation Electrical controls can be adapted match your existing PLC network protocols

Q3 What is the expected operational lifespan major components?
With proper maintenance industry data shows core structural components last15+ years Major crushers screens have10+ year design life Wear parts like jaw liners impact hammers screen meshes are consumables their lifespan depends directly on throughput material abrasiveness typically ranging from6 months24 months

S4 Bolehkah anda memberikan jaminan prestasi?
Yes Our proposals include guaranteed minimum throughput capacity under defined conditions guaranteed final product gradation We stand behind our equipment performance these metrics are contractually stipulated based on preagreed feedstock samples analysis

Q5 What does typical installation commissioning involve?
For skidmounted plants it involves site preparation foundation bolting electrical power cable connection For stationary plants it includes more extensive civil work Our team provides supervision commissioning support operator training We manage the process until plant acceptance signoff