1. PEMBUKAAN PAINPOINT DRIVEN

Adakah operasi pengendalian sanga anda merupakan kesesakan yang berterusan dan punca kos tersembunyi? Untuk pengurus loji dan kontraktor kejuruteraan, cabaran pemprosesan sanga metalurgi adalah pelbagai rupa. Adakah anda mengalami:
Excessive Downtime: Frequent clogging, merapatkan, and abrasive wear in primary crushing stages halting your entire material recovery line?
Throughput Tidak Diramalkan: Inconsistent feed size and composition from ladles leading to capacity fluctuations and missed processing targets?
Kos Operasi yang Tinggi: Premature failure of crusher components not designed for extreme abrasion, coupled with high energy consumption per ton processed?
Ketidakcekapan Pemulihan: Inadequate liberation of metallic fractions from the slag matrix, leaving valuable material in your waste stream and reducing overall plant revenue?
Keselamatan & Maintenance Burdens: Laborintensive clearing of jams and the risks associated with manual handling of large, irregular slag pieces?

Isu ini secara langsung memberi kesan kepada pendapatan anda melalui kehilangan pengeluaran, increased maintenance labor, and suboptimal metal recovery. Soalan intinya ialah: bagaimana anda mencapai kebolehpercayaan, highvolume slag reduction with predictable operating costs?

2. GAMBARAN KESELURUHAN PRODUK: LOJI PENGHANCUR SLAG

A Slag Crusher Plant is a purposebuilt, sistem pemprosesan pegun atau semimobil yang direka bentuk untuk yang utama, sekunder, and sometimes tertiary reduction of aircooled or granulated metallurgical slag. Its function is to liberate entrapped metal (ferrous and nonferrous) from the slag matrix and produce a consistently sized aggregate for sale or further processing.

Aliran Kerja Operasi:
1. Suapan & PraSkrining: Runoffurnace slag is fed via loader or conveyor into a robust grizzly or scalping screen to remove fine material (30mm) memintas penghancur utama.
2. Penghancuran utama: Material bersaiz besar (+30mm to +500mm) enters a heavyduty jaw crusher or impact breaker designed to handle extreme shock loads and abrasion.
3. Pemisahan Logam & Menghancurkan sekunder: The crushed product is conveyed past an overhead magnetic separator to extract liberated ferrous metal. Remaining material may pass through a secondary cone or impact crusher for final sizing.
4. Saiz Akhir & Stok: Material is screened into specified aggregate fractions (mis., 05mm, 510mm, 1020mm) melalui skrin bergetar dan dihantar ke simpanan.

Skop Permohonan & Batasan:
Skop: Ideal untuk loji keluli bersepadu, peleburan tembaga, pengeluar ferroalloy, dan halaman pemprosesan sanga kendiri yang mengendalikan relau letupan (BF), relau oksigen asas (BOF), relau arka elektrik (EAF), ladle, dan sanga bukan ferus.
Batasan: Not designed for primary rock mining applications. Performance on extremely sticky or highmoisture slags may require predrying or specialized feed systems.

3. CIRI TERAS

Penghancur Utama Tugas Berat | Asas Teknikal: Rahang Keluli Mangan Tinggi & Bingkai Bertetulang | Faedah Operasi: Sustained performance under extreme shock loads from large, irregular slag pieces with minimal deformation | Kesan ROI: Reduces unplanned crusher downtime by up to 40% and extends jaw life by over 60% berbanding reka bentuk standard.

Litar Pemisahan Magnet Bersepadu | Asas Teknikal: Overband SelfCleaning Electromagnets positioned at optimal discharge points | Faedah Operasi: Berterusan, automated recovery of liberated ferrous metal directly from the crushed stream without manual intervention | Kesan ROI: Meningkatkan kadar pemulihan logam dengan 1525%, creating a direct revenue stream from what was previously waste.

Sistem Aliran Bahan Tahan Lelasan | Asas Teknikal: Pelapik keluli AR400/500 dalam corong, jatuh, and skirts; impact beds on conveyor load zones | Faedah Operasi: Dramatically reduces wearrelated failures in highimpact areas, maintaining consistent flow geometry | Kesan ROI: Menurunkan kos penggantian pelapik tahunan secara purata sebanyak 35% and reduces conveyor belt damage.

Automasi PLC Berpusat & Pemantauan | Asas Teknikal: Programmable Logic Controller with HMI touchscreen for system control; motor current sensors and bearing temperature monitors | Faedah Operasi: Enables oneoperator control of the entire plant with realtime alerts for abnormal conditions like overloads or blockages | Kesan ROI: Optimizes power consumption per ton by up to 20% through controlled sequencing; reduces required operational manpower.

Reka Bentuk SkidMounted Modular (Pilihan) | Asas Teknikal: Preassembled crusher modules on heavyduty structural skids with integrated walkways | Faedah Operasi: Significantly reduces civil works requirements and onsite installation time by up to 70% | Kesan ROI: Pentauliahan yang lebih pantas mempercepatkan masa bagi hasil; facilitates future relocation if site requirements change.

Dedicated Slag Crusher Plant Dust Suppression System | Asas Teknikal: Nozzle arrays at transfer points connected to a highpressure pump unit with moisture sensors | Faedah Operasi: Effectively controls fugitive dust at source without overwetting material which can cause downstream handling issues | Kesan ROI: Ensures compliance with site environmental standards; protects other machinery from abrasive dust ingress.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penyelesaian Standard Industri | This Slag Crusher Plant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Adanya / Masa aktif| ~7580%, frequent jamming/clogging incidents| >92%, engineered feed system & crushing chamber design| +15% ketersediaan operasi|
| Kos Pakai setiap Tan Diproses| Kebolehubahan yang tinggi; frequent liner/impeller changes| Predictable cost; extendedlife components documented| 35% pengurangan purata|
| Kecekapan Pemulihan Logam (%)| Manual picking postcrushing or singlestage magnetic separation| Multistage liberation with optimized magnetic separation points| +20% ferrous recovery yield|
| Penggunaan tenaga (kWj/Tan)| Often overlooked; oversized motors running constantly| PLCcontrolled optimized start/stop sequences & VFD pada penyuap| 18% pengurangan purata|
| Pemasangan / Masa Pentauliahan| Extensive field fabrication & penjajaran (1216 minggu)| Pretested modular skids requiring connection only (68 minggu)| 50% site construction time|

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 50 TPH berakhir 300 TPH sanga yang diproses.
Pilihan Penghancur Utama: Kursus rahang (900 x 600mm to 1500 x 1200mm) or Primary Impact Crusher with hydraulic adjustment.
Keperluan kuasa: Jumlah beban bersambung biasanya antara 250 kW – 800 kW bergantung pada konfigurasi; supplied for 415V/3Phase/50Hz or as specified.
Spesifikasi Bahan Utama:
Crusher Jaws/Hammers/Blow Bars: Keluli Mangan Premium (1822% Mn).
Liners/Chutes/Wear Plates: Minimum AR400 Steel.
Structural Frames & Skids: HeavyDuty Pentaplate / IS2062 E350 Grade Steel.
Belting Penghantar: Minimum EP630/4 rated for abrasion resistance.
Dimensi Fizikal (Typical Modular Plant): Length ~40m x Width ~12m x Height ~9m (tidak termasuk corong suapan).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 10°C hingga +45°C; dust suppression system maintains operation within PM10 emission standards.

6. SENARIO APLIKASI

Loji Keluli Bersepadu – Pemprosesan Sanga BOF

Cabaran: A major steel producer faced severe bridging in their existing crusher feed hopper when processing large BOF slag lumps (>800mm), menyebabkan masa henti harian. Metal recovery was inefficient using a single magnet after crushing.
Penyelesaian: Implementation of a custom Slag Crusher Plant featuring a vibrating grizzly feeder with stepped grizzly bars to break bridges ahead of a deepchambered jaw crusher. Two overband magnets were installed—one precrusher for loose metallics and one postprimarycrusher.
Keputusan: Bridging incidents eliminated entirely. Ketersediaan tumbuhan meningkat daripada 78% ke >94%. Ferrous metal recovery improved by 22%, paying back the system’s capital cost in under two years through recovered metal value alone.

Kontraktor Pemprosesan Sanga Bebas

Cabaran: A contractor servicing multiple smalltomedium EAF mills needed a portable solution that could be relocated between sites every 1824 months but required consistent high throughput without lengthy setup times.
Penyelesaian: A fully skidmounted Slag Crusher Plant was supplied on four modular sections (feed module with scalper, primary crusher module, screening/magnet module). All modules featured quickdisconnect electrical/pneumatic connections.
Keputusan: Relocation time between sites reduced from three months to four weeks due to minimal civil work required at new locations. Consistent throughput of ~120 TPH maintained across different site configurations.

7. PERTIMBANGAN KOMERSIL

Our Slag Crusher Plants are offered in three primary tiers based on capacity and automation level:

1. Loji Tugas Standard (<100 Tph): Focuses on core reliability with essential features like primary crushing and magnetic separation—ideal for smaller operations prioritizing capital efficiency.
2. Loji Tugas Berat (100 – .200 Tph):) Our most common configuration includes full abrasion protection package advanced PLC automation multistage sizing/screening—designed for maximum total costofownership savings in continuous operation
3.
4.HighCapacity/Turnkey System (>200 Tph):) Includes all heavyduty features plus optional secondary crushing stage automated sampler complete dust collection baghouse system project management services

Ciri Pilihan termasuk:
Sistem pelinciran gris automatik
Thermal camera monitoring for bearings
Advanced aggregate cubicity shaping kit
Onboard diesel generator power pack

Service Packages range from basic commissioning/spare parts supply upto comprehensive annual maintenance contracts including scheduled wear part replacement

Financing options including equipment leasing rentalpurchase agreements are available subjecttoqualification providing flexibilityincapitalexpenditureplanning

8.Soalan Lazim:

Q1 How do I determine if my specific typeofslag requiresajawcrushersoranimpactcrushersastheprimaryunitintheslagcrushersplants?
A1 The choice dependsonslag characteristics Jaw crushers are generally preferredforhighlyabrasive dense slagswithcompressivestrengthlikeaircooledBFslag duetotheirdirectforceandslowerspeed minimizing wear Impactors can offer higher reduction ratiosandbetter particle shapeforlessabrasive slags like someEAFslag We analyze your samplematerialin our labtoprovideadatabacked recommendation

Q2 Whatisthetypicalinstallationfootprintandfoundationrequirementsforaskidmountedslagcrushersplants?
A2 While significantly reduced comparedtotraditional plants level compacted groundoraminimalconcretethicknesspadissufficientforskid placement Major civil workislimitedtofeedhopperpitsandfinalproducttunnelconveyors if applicable Detailed foundation drawings are providedforsitepreparation

Q3 CananexistingslagcrushersplantsbeupgradedwithyourkeyfeaturesliketheenhancedmagneticcircuitorPLCautomations?
A3 Yes many components suchasoverbandmagnets advancedlinersandcontrol systems can be retrofitted ontoexistinginfrastructure Our engineers can conductanauditofyourcurrentsetupandproposephasedupgradestoimproveperformanceandROI

Q4 Howdoyouquantifythepotentialmetalrecoveryimprovementbeforepurchases?
A5 We conductarepresentativesampletestingprograminvolvinglaboratoryscalecrushingandmagneticseparationonyoursuppliedslag This generatesametallurgicalbalancereportprojectingliberationratesandrecoverypotentialwithdifferentmachineconfigurations providinganevidencebased forecast

Q5 Whatistheleadtimefromordertocommissioningforastandardheavydutyslagcrushersplants?
A6 Forstandarddesignsintheheavydutyrange leadtimesaveragebetweenfivesevenmonths This includesmanufacturing factorytesting disassemblyforshipmentandreassemblyonyoursite Modularskiddedunits reduceonsiteassemblytimebyoverhalfcomparedtopiecebuilt plants