1. PEMBUKAAN PAINPOINT DRIVEN

Managing slag stockpiles is a persistent operational and financial drain. Adakah anda menghadapi cabaran biasa ini?
Kehilangan Logam Tidak Dipulihkan: Valuable ferrous and nonferrous metals trapped in slag represent direct revenue loss with every ton processed.
Inefficient Processing: Manual breaking or underpowered crushers lead to bottlenecks, limiting your plant’s overall throughput and creating storage headaches.
Masa Henti yang Tinggi & Penyelenggaraan: Frequent breakdowns from abrasive slag cause unplanned stoppages, escalating repair costs and labor hours.
Inconsistent Output Size: Poorly sized material complicates downstream handling, pemisahan magnet, and final product saleability.
Angkasa & Liability Constraints: Growing slag yards consume valuable real estate and present longterm environmental management concerns.

How do you transform this liability into a controlled, profitable recovery stream while ensuring system reliability? Jawapannya terletak pada kilang penghancur sanga yang direka khas.

2. GAMBARAN KESELURUHAN PRODUK

A slag crusher plant is a stationary or semimobile processing system designed specifically for the size reduction and liberation of metallurgical slag (relau letupan, relau keluli, Tembaga, dll.). Its primary function is to crush large slag lumps into uniform, graded aggregates to maximize metal recovery via magnetic or eddy current separation.

Aliran Kerja Operasi:
1. Suapan & PraSkrining: Raw slag from stockpile is fed via loader; an initial grizzly screen removes fine material bypassing the primary crusher.
2. Penghancuran utama: A heavyduty jaw crusher reduces large lumps (often up to 1000mm) kepada saiz yang boleh dikawal (lebih kurang. 150200mm).
3. Menghancurkan sekunder & Pemeriksaan: A cone or impact crusher further reduces material, which is then screened to separate correctly sized product.
4. Pemisahan Logam: Sized material passes over suspended magnets or an eddy current separator to extract ferrous and nonferrous metals.
5. Stok: Cleaned aggregate is conveyed to stockpiles for sale or reuse; recovered metal is collected for recycling.

Skop Permohonan & Batasan:
Skop: Ideal untuk loji keluli bersepadu, faundri, peleburan, and standalone metal recovery facilities processing blast furnace (BF) Slag, mencuri strok (strok LD), dan sanga bukan ferus.
Batasan: Not designed for primary rock mining or extremely highsilica content materials without specific liner configurations. Feed size must be controlled within crusher intake dimensions.

3. CIRI TERAS

Penghancur Rahang Tugas Berat | Asas Teknikal: Rahang keluli mangan tinggi dengan sudut nip yang dioptimumkan | Faedah Operasi: Mengendalikan besar, ketulan sanga yang tidak teratur dengan daya mampatan yang tinggi; meminimumkan penjembatan | Kesan ROI: Reduced primary stage blockages increase uptime by an estimated 1520%, lowering labor for manual clearing.

Pelapik Tahan Lelasan & Komponen | Asas Teknikal: AR400/500 steel plates, replaceable wear parts in critical zones | Faedah Operasi: Memanjangkan hayat perkhidmatan dalam persekitaran yang sangat kasar; components are modular for easier replacement | Kesan ROI: Data lapangan menunjukkan a 3040% reduction in liner changeout frequency compared to standard carbon steel.

Sistem Pemisahan Magnet Bersepadu | Asas Teknikal: Overband selfcleaning electromagnet or permanent magnet positioned postcrushing | Faedah Operasi: Automatically extracts liberated ferrous metal directly from the crushed material stream | Kesan ROI: Increases pure metal recovery rates by up to 812%, turning waste into direct revenue.

Centralized Greasing & Sistem hidraulik | Asas Teknikal: Automated lubrication points for bearings and hydraulic adjustment/tramp release on crushers | Faedah Operasi: Ensures critical components are protected from dust ingress; allows quick clearing of uncrushables | Kesan ROI: Predictive maintenance schedules reduce bearing failures by an estimated 25%, mencegah kerosakan sekunder yang mahal.

Vibrating Screen with Deck Options | Asas Teknikal: HighG multideck screen with wire mesh or polyurethane panels | Faedah Operasi: Provides precise sizing of crushed aggregate for optimal market value or downstream processing | Kesan ROI: Consistent product sizing can increase aggregate sales revenue by improving specification compliance.

Robust Structural Base Frame | Asas Teknikal: Fabricated steel frame with antivibration pads and reinforced supports under heavy units | Faedah Operasi: Provides longterm stability under dynamic loads, reducing stress fractures and misalignment | Kesan ROI: Minimizes foundational repairs and ensures consistent operational geometry over the plant's lifetime.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penyelesaian Standard Industri | Penyelesaian Loji Penghancur Sanga Kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Kadar Pemulihan Logam| Standalone crusher with separate magnetic pulley| Integrated primary crushing + overband magnet + secondary separation circuit| +1015% total metal yield |
| Liner Life in Abrasive Slag| Pelapik keluli mangan standard| Multialloy composite liners & strategic wear protection design| +35% average lifespan |
| Ketersediaan Masa Beroperasi Sistem| Multiple standalone units with transfer points| Streamlined plant layout with reduced transfer points & kawalan berpusat| +8% ketersediaan operasi |
| Penggunaan Kuasa setiap Tan| Pemacu kelajuan tetap merentasi semua motor| Configured VFDs on conveyors and secondary crusher based on load| 12% penggunaan tenaga tertentu |
| Jejak setiap Kapasiti TPH| Spreadout equipment requiring more land area| Padat, modular design integrating feeding, menghancurkan & screening on single base frame| 20% space requirement |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 50 TPH kepada 300+ Daya pengeluaran TPH.
Penghancur utama: Jaw Crusher Model range; Feed Opening up to 1200mm x 900mm; Julat CSS 150250mm.
Penghancur sekunder: Cone Crusher or Impact Crusher options based on slag hardness and desired shape.
Keperluan kuasa: Total installed power typically between 150kW 450kW depending on configuration (3fasa, 50/60Hz).
Spesifikasi Bahan Utama: Bingkai utama (IS 2062 keluli struktur), Chute/hopper liners (1012mm AR400 Steel), Tali pinggang penghantar (EP630/4 minimum).
Dimensi Fizikal (Tumbuhan Biasa): Length ~2535m; Width ~812m; Height ~69m (tidak termasuk corong suapan).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 10°C hingga +45°C; dust suppression system compliant with local regulations.

6. SENARIO APLIKASI

Loji Keluli Bersepadu – Pemprosesan Sanga Relau Letupan

Cabaran: A major steel producer faced low metal recovery from old BF slag dumps using rented mobile equipment, leading to high perton costs and inconsistent output hampering aggregate sales.
Penyelesaian: Installation of a dedicated 200 TPH stationary slag crusher plant featuring a heavyduty jaw crusher, twostage screening, and dual magnetic separation stages.
Keputusan: Achieved consistent metal recovery rate of over 96%. Produced certified aggregate for road construction. Tempoh bayaran balik dicapai dalam bawah 18 months through combined metal revenue and aggregate sales.

Pelebur Tembaga – Sanga Relau Berkumandang

Cabaran: A smelter needed to process historically stockpiled copperrich slag fines (<30mm) that were bypassing their primary crushing circuit but still contained valuable copper matte particles.
Penyelesaian: Implementation of a specialized secondary circuit using a fine cone crusher in closed loop with screens to liberate locked copper particles before advanced separation techniques.
Keputusan:Liberated an additional estimated copper content worth significant annual revenue from "waste" material previously considered uneconomical to process further.

Independent Metal Recovery Contractor

Cabaran:A contractor servicing multiple small foundries required a relocatable solution that could be set up quickly on different sites without major civil works while maintaining robust performance.
Penyelesaian:Semimobile skidmounted slag crushing plant with integrated feed conveyor,magnet,and onboard power pack.All modules designed for transport on standard trailers.
Keputusan:Mobilization time reduced from weeks to days.Plant demonstrated consistent performance across three different site materials within the first year,maximizing equipment utilization rates

7.PERTIMBANGAN KOMERSIL

Our approach provides clarity around investment:

• Pricing Tiers:
Base Plant(penghancuran utama,magnet,saringan asas):Competitive entrylevel solution
Enhanced Plant(+menghancurkan sekunder,fine screening,penindasan habuk):Recommended for maximum recovery&nilai produk
Custom Turnkey System(+feed systems,final product conveyors,silo):Complete handling solution

• Ciri Pilihan:Dust extraction bag houses,wash systems for aggregate polishing,tramp metal detectors,belt scalesfor production weighingautomated control cabins

• Pakej Perkhidmatan:
Kontrak Penyelenggaraan Tahunan:Meliputi pemeriksaan berjadual,pelincir,and wear part discounts
OnDemand Support:Flexible technical supportand field service visits
• Operator Training Programs

• Financing Options Available including leasetoown structuresand equipment financing through partners enabling capital preservation

Soalan Lazim

S1:What types of slags can this plant process effectively?
A1:The plants are engineered primarily formetallurgical slags including blast furnace(BF)and basic oxygen furnace(BOF/LD)slag.They can also be configuredfor nonferrous slags(Tembaga,Nikel).Highly siliceous materials may require specific wear material consultation

S2:What level of foundationor civil workis requiredfor installation?
A2:The modular design requiresa level compacted ground pad.A concrete foundationis strongly recommendedfor longterm stabilityof stationary plants.Semimobile skid versionsrequire minimal preparation.Detailed foundation drawingsare providedwith purchase

S3:What kindof output sizescan we expectfromthe crushedaggregate?
A3 Output sizingis fully configurablebasedon screen deck selection.Typical product rangesinclude05mm510mm1020mmand2040mm fractions meetingmost constructionaggregate specifications

Q4 How doesyourplant handle trampmetalor uncrushablematerialthat may enterwiththe feed?
A4 The primaryjawcrusheroften includesa hydraulic toggle relief systemthat automaticallyreleases the jaws topass uncrushablematerial preventing catastrophic damage Additionallymetal detectorscanbe installedas an optionto stopthe feed beltbefore damage occurs

Q5 Whatisthe typical leadtimefrom orderto commissioning?
A5 For standardplant configurationslead timesrange between14to22weeksdependingon complexity Customturnkey projectsmay require longer Detailedproject timelinesare establishedduringthe quotation phase