1. PEMBUKAAN PAINPOINT DRIVEN

Menguruskan sanga adalah kesesakan yang berterusan dengan kos yang ketara. Adakah anda menghadapi cabaran operasi ini?
Throughput Tidak Boleh Dipercayai & Downtime: Inconsistent feed size and tramp metal cause frequent jams in standard crushers, halting your entire material recovery line and delaying downstream processing.
Pemakaian Berlebihan & Kos penyelenggaraan: The highly abrasive nature of slag rapidly degrades standard manganese steel components, leading to unscheduled shutdowns and high spare part expenditures.
Inefficient Liberation of Valuables: Inadequate crushing fails to fully liberate metallic fractions (ferrous and nonferrous) from the slag matrix, leaving recoverable value in your waste stream and reducing overall plant revenue.
habuk & Environmental Control Issues: Dry crushing processes generate significant fugitive dust, creating environmental compliance risks and unsafe working conditions for personnel.

If these issues are impacting your profitability, the central question is: bagaimana anda mencapai konsisten, highvolume slag reduction with lower operational costs and maximized metal recovery? Jawapannya terletak pada purposeengineered Loji Penghancur sanga.

2. GAMBARAN KESELURUHAN PRODUK

A Loji Penghancur sanga is a stationary or semimobile processing system specifically engineered for the primary, sekunder, and sometimes tertiary crushing of metallurgical slag (relau letupan, relau keluli, Tembaga, dll.). Its design prioritizes durability against abrasion and impact while ensuring efficient liberation of entrapped metals.

Aliran Kerja Operasi:
1. Suapan & PraSkrining: Runofpile slag is fed via loader or conveyor into a vibrating grizzly feeder, yang menghilangkan pecahan halus (30mm) untuk memintas penghancur utama, increasing system efficiency.
2. Penghancuran utama: Oversize material is reduced by a heavyduty jaw crusher or impactor designed for high compressive strength feed.
3. Pemisahan Logam & Menghancurkan sekunder: The crushed product typically passes over an overhead magnetic separator to remove liberated ferrous scrap. The remaining material is further reduced by a cone crusher or secondary impactor to achieve the target grain size (mis., 20mm).
4. Saiz & Stok: A final vibrating screen classifies the product, dengan bahan bersaiz besar diedarkan semula. Onspec material is conveyed to stockpile for sale as aggregate or for further processing.

Skop Permohonan: Ideal untuk loji keluli bersepadu, peleburan, kawasan pemprosesan sanga, and aggregate producers handling ferrous and nonferrous slags.

Batasan: Not designed for primary mining of virgin rock or for processing materials with extreme moisture or clay content without preconditioning.

3. CIRI TERAS

Penyumpan Grizzly Bergetar Tugas Berat | Asas Teknikal: Highstrength eccentric shaft drive | Faedah Operasi: Removes fines upfront, regulates feed to the primary crusher preventing chokefeeding | Kesan ROI: Reduces primary crusher load by up to 30%, lowering wear and energy consumption per ton processed.

AbrasionResistant Liner Packages | Asas Teknikal: Airhardening manganese steel or composite ceramic/metal alloys | Faedah Operasi: Hayat pelapik dilanjutkan oleh 4060% compared to standard manganese in highabrasion zones | Kesan ROI: Decreases downtime for liner changes and reduces annual spare parts inventory cost.

Litar Pemisahan Magnet Bersepadu | Asas Teknikal: Overband selfcleaning magnets positioned at optimal discharge points | Faedah Operasi: Continuously extracts liberated ferrous metal during crushing stages | Kesan ROI: Creates a direct revenue stream from scrap recovery and protects downstream conveyors and crushers from metal damage.

Centralized Greasing & Sistem hidraulik | Asas Teknikal: Automated lubrication points for bearings and hydraulic adjustment/tramp release systems | Faedah Operasi: Ensures critical components are lubricated under all operating conditions; allows quick clearing of uncrushables | Kesan ROI: Menghalang kegagalan galas bencana (a major cause of downtime) and minimizes manual maintenance intervention time.

Integrasi Sistem Penindasan Habuk | Asas Teknikal: Nozzle arrays at transfer points connected to water supply with solenoid control | Faedah Operasi: Effectively controls dust emissions at source during crushing operations | Kesan ROI: Mengurangkan risiko ketidakpatuhan alam sekitar dan mengurangkan kos buruh pengemasan.

Robust Structural Fabrication | Asas Teknikal: Stiffened frame design with heavyduty crawler or fixed plant support legs | Faedah Operasi: Maintains alignment under continuous highvibration loads over years of operation | Kesan ROI: Eliminates costly structural repairs and prevents premature failure of mounted components due to frame flexing.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penyelesaian Standard Industri | Penyelesaian Loji Penghancur Sanga Kami | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Adanya / Masa aktif | 8085%, frequent jamming from tramp metal >8592%, hydraulic tramp release clears uncrushables in 8% bertambah |
| Kehidupan Pelapik di Peringkat Utama (Mn Steel) ~40,000 MT throughput ~60,000 MT throughput >50% penambahbaikan |
| Specific Power Consumption ~0.8 1.0 kWh/ton ~0.65 0.75 kWj/tan >20% pengurangan |
| Metal Recovery Efficiency Manual picking postcrushing Inprocess magnetic separation at 2 stages Scrap recovery yield increased by 1525% |
| Dust Emission at Transfer Points Dry crushing with local extraction Wet suppression system at source PM10 emissions reduced by >90% |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 50 TPH berakhir 300 TPH sanga diproses.
Keperluan kuasa: Jumlah kuasa terpasang biasanya berkisar dari 150 kw (untuk 50 loji TPH) ke 450 kw (untuk 300 loji TPH), bergantung kepada konfigurasi.
Spesifikasi Bahan: Primary crusher jaws/liners manufactured from premiumgrade Manganese Steel (1822%). Critical wear plates utilize AR400 steel. Structural frames fabricated from heavyduty ISMC/ISMB sections.
Dimensi Fizikal (tipikal 150 Tumbuhan tph): Panjang (~25m) X lebar (~8m) x Tinggi (~7m). Available in fixed skidmounted or semimobile trailer versions.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +50°C. Sistem penindasan habuk memerlukan bekalan air bersih di 3040 Psi; consumption approx. 50 liters per ton crushed.

6. SENARIO APLIKASI

Cabaran Laman Slag Loji Keluli Bersepadu:

A major steel producer faced inconsistent feed from aged stockpiles causing daily chokeups in their existing crusher, limiting aggregate production to just one shift per day due to maintenance needs.

Penyelesaian:

Implementation of a turnkey Loji Penghancur sanga featuring an extradeep crushing chamber jaw crusher with hydraulic toggle adjustment for quick CSS changes, paired with a powerful overhead magnet on the primary discharge belt.

Keputusan:

Plant availability increased to three full shifts. Aggregate production rose by 210%. Recovered ferrous scrap generated sufficient revenue to cover the plant’s operating labor costs annually.

Copper Smelter Tailings Reprocessing Challenge:

A smelter sought to recover residual copper from old dump slag but found that conventional hammer mills created excessive fines (3mm), rendering gravity separation ineffective.

Penyelesaian:

A twostage Loji Penghancur sanga using a jaw crusher followed by a cone crusher in closed circuit with a screen was deployed for controlled size reduction targeting 12mm+3mm.

Keputusan:

The optimized grain size distribution improved recovery rates in the downstream jig plant by over 18%. The robust design handled the highly abrasive silicarich slag with liner life meeting projected targets.

7. PERTIMBANGAN KOMERSIL

Peringkat Harga: Solutions are projectspecific but generally fall into three categories:
Standard SkidMounted Plant (50100 Tph): A costeffective entry point for lower volume processors.
Modular MediumCapacity Plant (100200 Tph): The most common configuration offering optimal balance of output and investment.
HighCapacity Fixed Stationary Plant (200300+ Tph): Designed for largescale producers requiring maximum uptime and automation.
Ciri Pilihan: Vibrating feeder vs apron feeder; secondary cone vs impact crusher; automated metal detection system; advanced PLC control panels with remote monitoring capability; sound enclosures.
Pakej Perkhidmatan: Pelan jaminan lanjutan; kontrak pemeriksaan tahunan; guaranteed spare parts delivery schedules (mis., 48hour critical parts availability).
Pilihan Pembiayaan: Struktur pemajakan peralatan melalui institusi kewangan rakan kongsi; milestonebased project payment plans for turnkey installations.

8. Soalan Lazim

1. Is your Slag Crusher Plant compatible with our existing conveyors and material handling infrastructure?
Our engineering team can design transfer heights and discharge points to match your current layout during the project specification phase.

2. Apakah tahap hingar operasi yang dijangkakan?
With standard equipment enclosures, pengukuran medan biasanya menunjukkan tahap di bawah 85 db(A) at a distance of one meter from the machinery when processing dry slag.

3. How long does installation take?
For a skidmounted plant delivered preassembled on our frames, onsite commissioning can be completed within two weeks after foundation readiness upon arrival at your site

4.Bolehkah anda memberikan jaminan prestasi?
Yes we offer guaranteed minimum throughput capacity based on defined feed material characteristics as well as maximum power consumption per ton

5.What are typical payment terms?
For custom plants terms are generally structured as follows
30% advance payment
60% against dispatch
10% after successful commissioning

6.Do you offer training for our operators
Comprehensive training covering operation routine maintenance safety procedures troubleshooting is provided onsite during commissioning

7.How do you handle warranty claims
We maintain regional service hubs Warranty claims initiate through our service manager who coordinates diagnostics part dispatch if needed technician deployment if required