1. PEMBUKAAN PAINPOINT DRIVEN

Menguruskan sanga adalah kesesakan yang berterusan dengan kos yang ketara. Adakah anda menghadapi cabaran operasi ini?
Throughput Rendah & Masa Henti yang Tinggi: Inefficient or undersized crushing circuits create a backlog, delaying material handling and tying up valuable site space. Every hour of crusher downtime impacts downstream processing revenue.
Pemakaian Berlebihan & Kos penyelenggaraan: Sifat kasar sanga dengan cepat merendahkan komponen penghancur standard, membawa kepada perubahan pelapik yang kerap, unplanned maintenance stops, and soaring spare parts expenditure.
Pengurangan Saiz Tidak Boleh Dipercayai: Inconsistent feed size and variable slag hardness can cause plugging, poor discharge gradation, and product that fails to meet specification for resale or further processing.
Kerumitan Operasi yang Tinggi: Plants requiring multiple stages of prescreening, manual breaking, or secondary crushing add labor costs and points of failure.

Soalan teras untuk pengurus loji ialah ini: bagaimana anda mencapai konsisten, highvolume slag reduction with predictable operating costs and minimal disruption? Jawapannya terletak pada kilang penghancur sanga yang direka khas.

2. GAMBARAN KESELURUHAN PRODUK

A slag crusher plant is a stationary or semimobile integrated processing system designed specifically for the primary and secondary reduction of metallurgical slag (relau letupan, relau keluli). Ia berubah menjadi besar, irregular slag chunks into a precisely graded aggregate for use in construction, Pangkalan jalan, or as a feedstock for further metal recovery.

Aliran Kerja Operasi:
1. Suapan & PraSkrining: Runoffurnace slag is fed via loader into a hopper, often with a grizzly section to bypass subsize material directly to the discharge conveyor.
2. Penghancuran utama: A heavyduty jaw crusher or impact breaker applies compressive force to break down large slabs (often up to 1m+) ke dalam serpihan yang boleh diurus.
3. Pemindahan Bahan & Menghancurkan sekunder: A network of belt conveyors transports material to a secondary cone crusher or impactor for final size refinement.
4. Saiz & Stok: The crushed product passes over vibrating screens to separate it into specified grades (mis., 05mm, 520mm, 2040mm), which are then stockpiled via radial or stacker conveyors.

Skop Permohonan & Batasan:
Skop: Ideal untuk loji keluli bersepadu, peleburan, tapak sekerap, and dedicated slag processing facilities handling ferrous and nonferrous slags.
Batasan: Not designed for primary rock mining or extremely highmoisture materials without preconditioning. Feed size must be compatible with the primary crusher’s inlet dimensions.

3. CIRI TERAS

Penghancur Utama Tugas Berat | Asas Teknikal: Robust manganese steel jaws/liners with optimized nip angle | Faedah Operasi: Handles extreme shock loads from irregular slag feed without failure; mengurangkan penyambungan | Kesan ROI: Higher uptime and lower risk of catastrophic damage versus modified quarry crushers.

Sistem Penghantaran Tahan Lelasan | Asas Teknikal: Impact beds at loading points; SBR/antitear conveyor belting; hardened alloy pulley lagging | Faedah Operasi: Dramatically reduces belt wear and puncturerelated stoppages | Kesan ROI: Data lapangan menunjukkan a 4060% increase in belt service life, cutting replacement costs and labor.

Scalping Bersepadu & pintasan | Asas Teknikal: Grizzly feeder or vibrating prescreen section before primary crusher | Faedah Operasi: Removes fines and subsize material from the crushing circuit, meningkatkan kapasiti berkesan | Kesan ROI: Prevents crusher overload and reduces energy consumption per ton of processed material.

Sistem Kawalan PLC Berpusat | Asas Teknikal: Automated startup/shutdown sequences with load monitoring and fault diagnostics | Faedah Operasi: Enables operation by one person from a control cabin; provides clear alerts for maintenance triggers | Kesan ROI: Reduces labor requirements and allows for predictive maintenance scheduling to avoid unplanned downtime.

Reka Bentuk Struktur Modular | Asas Teknikal: Bolttogether heavy steel sections on prepared foundation | Faedah Operasi: Faster installation and commissioning compared to weldedsite builds; membenarkan konfigurasi semula atau penempatan semula pada masa hadapan | Kesan ROI: Cuts civil engineering costs and gets the plant operational weeks sooner.

Sistem Penindasan Habuk Deduced | Asas Teknikal: Muncung semburan diletakkan secara strategik dengan injap solenoid yang diikat pada operasi penghantar | Faedah Operasi: Effectively controls dust at transfer points without overwetting the product | Kesan ROI: Ensures compliance with site environmental standards and protects worker health and machinery.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Modified Quarry Plant) | Penyelesaian Loji Penghancur Sanga Kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Pelapik/Sebahagian Hayat Pakai (Utama) | 6090 days under severe duty | 120180 days under severe duty | +100% penambahbaikan |
| Ketersediaan Sistem (Masa aktif) | ~8085%, frequent minor stoppages| Sasaran >92%, designed for reliability| +812% peningkatan mutlak |
| Tons Processed per KWh| Berbeza secara meluas; selalunya tidak cekap| Optimized circuit reduces recrush| Hingga 15% energy saving |
| Desired Product Yield| Often requires recrushing of oversize| Accurate sizing via tuned screen decks| Yield improvement of 510% |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 50 TPH berakhir 300 Daya pengeluaran nominal TPH.
Keperluan kuasa: Jumlah kuasa terpasang biasanya antara 150 kw 450 kW bergantung pada konfigurasi; supplied for 400V/50Hz or other industrial standards.
Spesifikasi Bahan: Crusher liners in Mn18Cr2/Mn22Cr2 steel; structural frames in S355JR grade steel; keluli tahan lelasan (AR400) pada titik haus kritikal.
Dimensi Fizikal (Contoh 150 Tumbuhan tph): Anggaran jejak 35m (L) x 18m (W); height ~12m. Custom layouts available.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C; sistem penindasan habuk dinilai untuk operasi yang berkesan sehingga 80% kelembapan relatif.

6. SENARIO APLIKASI

Kitar Semula Sanga Loji Keluli Bersepadu

Cabaran: A major mill faced chronic bottlenecks in clearing aircooled blast furnace slag. Their existing setup caused excessive conveyor belt damage and produced inconsistent aggregate sizes rejected by their concrete block manufacturing customer.
Penyelesaian: Implementation of a turnkey slag crusher plant featuring an impact primary crusher for slab breaking and a secondary cone crusher closedcircuit with a tripledeck screen.
Keputusan: Daya tampung meningkat sebanyak 140%. Product gradation met specification consistently (>95% hasil). Belt replacement costs fell by an estimated $25,000 annually due to the redesigned transfer points.

Kontraktor Pemprosesan Sanga Bebas

Cabaran: A contractor needed a mobile solution to process slag piles at multiple disused industrial sites. They required quick setup/teardown without sacrificing durability against abrasive material.
Penyelesaian: A semimobile skidmounted slag crusher plant with wheelmounted jaw crusher module and tracked screening module connected by extensible conveyors.
Keputusan: Site deployment time reduced from weeks to days. The plant maintained an availability rate above 90% across three different site contracts, enabling the contractor to fulfill volumebased agreements reliably.

7. PERTIMBANGAN KOMERSIL

Peringkat Harga: Investment scales with capacity and robustness.
Kewajipan Standard: Untuk volum rendah (<100Tph), less abrasive slags.
Tugas Berat: Our most common specification for highvolume ferrous slag processing (>150Tph).
Projek Turnkey: Includes civil works guidance, penyeliaan pemasangan, pentauliahan, dan latihan pengendali.
Ciri Pilihan: Metal detection/magnetic separation modules postcrushing; sistem pelinciran automatik; telematik pemantauan jarak jauh; sound enclosures.
Pakej Perkhidmatan: Kontrak penyelenggaraan tahunan berperingkat tersedia meliputi pemeriksaan berjadual, priority spare parts supply discounts (biasanya 1020%), and technical support access.
Pilihan Pembiayaan: We work with equipment financing partners to offer leasetoown plans or commercial loans tailored to capital expenditure cycles.

8. Soalan Lazim

1. Is your plant compatible with our existing feed system (mis., excavator/dump truck)?
ya. Hopper dimensions and heights are engineered based on your specific feeding equipment during the design phase to ensure efficient loading without modification.

2. What is the expected operational manpower requirement?
A welldesigned PLCcontrolled plant can be operated effectively by one control room operator per shift for normal running conditions.

3. How do you ensure wear part compatibility? Are they readily available?
We use industrystandard metric dimensions where possible (mis., common jaw crusher models). All critical wear parts are stocked in our regional warehouses with guaranteed availability under service contracts.

4. Apakah masa utama penghantaran biasa?
For standard configured plants after final design approval lead times range from XX weeks depending on complexity

5 Can we process wet or clinkerheavy slag?
The standard design handles aircooled denseslag optimally For very wet materials we recommend design modifications such as steeper hoppers screen deck heating elements which can be quoted as part of initial project scoping

6 What warranty is provided?
We offer X months warranty on all machinery against manufacturing defects Extended warranties are available through our service packages

7 Adakah anda menyediakan jaminan prestasi?
Yes we provide guaranteed minimum throughput capacity based on agreed feed material specifications as part of our turnkey project contracts