1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing a steel plant or slag processing yard and facing persistent bottlenecks in your material recovery chain? The challenges with traditional slag handling are quantifiable and costly. Inconsistent feed size jams crushers, causing unplanned downtime that costs thousands per hour in lost production and labor. Abrasive slag components rapidly wear out standard crushing chambers, membawa kepada kerap, expensive liner replacements and parts inventory burdens. Tambahan pula, inefficient separation results in valuable metallic content being lost to waste stockpiles, directly impacting your revenue recovery. Dust generation creates environmental and health compliance issues, while inflexible equipment cannot adapt to varying slag types or production demands.

Persoalan utama untuk pengurus loji adalah jelas: bagaimana anda boleh mencapai boleh dipercayai, highvolume slag processing with lower operating costs and maximized metal yield? The answer requires a purposeengineered system, not just a standard crusher.

2. GAMBARAN KESELURUHAN PRODUK

A Loji Penghancur sanga is a stationary or semimobile integrated processing system designed specifically for the size reduction and liberation of metallic content from steel slag, sanga relau letupan, and similar industrial byproducts. Ia berubah mentah, lump slag into a graded, marketable aggregate while recovering ferrous metal for recycling.

Aliran Kerja Operasi:
1. Penghancuran utama & Pemeriksaan: Ketulan sanga besar (sehingga 1000mm) are reduced by a primary jaw crusher. A preliminary screen removes fine material.
2. Pemisahan Magnetik (Utama): A suspended magnet over the conveyor extracts the majority of liberated ferrous metal postprimary crushing.
3. Menghancurkan sekunder: A cone crusher or impactor further reduces the material to achieve optimal liberation of embedded metal.
4. Saringan Akhir & Perpisahan: Material is classified into precise aggregate sizes (mis., 05mm, 510mm, 1020mm). A second drum magnet ensures final metal recovery.
5. Stok: Clean aggregate is conveyed to stockpiles; recovered metal is collected for sale or reuse.

Skop Permohonan: Integrated steel plants, kawasan pemprosesan sanga sendiri, mining operations handling abrasive materials.
Batasan: Not designed for highly corrosive chemical slags or as a primary ore processing plant without significant configuration changes.

3. CIRI TERAS

Penyuap Bergetar Tugas Berat | Asas Teknikal: Grizzly section with adjustable spacing | Faedah Operasi: Removes subgrade fines and prevents primary crusher overload | Kesan ROI: Mengurangkan kehausan penghancur sehingga 15% and improves overall throughput stability.

Jaw Crusher with Manganese Steel Jaws | Asas Teknikal: High compression crushing with optimized nip angle | Faedah Operasi: Effectively processes large, irregular slag lumps with high compressive strength | Kesan ROI: Data lapangan menunjukkan a 2030% longer service life compared to standard jaws in abrasive applications.

Electromagnetic Suspended Magnet | Asas Teknikal: Deep magnetic field penetration across full conveyor width | Faedah Operasi: Recovers large tramp metal sebelum ini secondary crushing stages | Kesan ROI: Protects downstream equipment from damage and captures highvalue scrap early in the process.

Liner Protection System (Cone/Impactor) | Asas Teknikal: Hydraulic adjustment and overload relief cylinders | Faedah Operasi: Allows quick clearing of uncrushables and protects major components from catastrophic failure | Kesan ROI: Minimizes risk of costly repairs and reduces mean time to repair (MTTR) by hours.

Penyampaian Tertutup & Titik Penindasan Debu | Asas Teknikal: Sealed transfer points with strategically placed spray nozzles | Faedah Operasi: Controls airborne particulate at critical generation points | Kesan ROI: Mitigates environmental noncompliance risks and reduces site cleanup costs.

Sistem Kawalan PLC Berpusat | Asas Teknikal: Automated sequencing with fault annunciation | Faedah Operasi: Enables smooth plant startup/shutdown and provides operators with clear diagnostic information | Kesan ROI: Lowers operator error potential and simplifies troubleshooting.

Reka Bentuk Skid Modular (Pilihan) | Asas Teknikal: Preassembled structural frames for key modules | Faedah Operasi: Reduces civil works cost and accelerates onsite installation time by an estimated 30% | Kesan ROI: Faster commissioning leads to earlier production revenue.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Slag Crusher Plant Solution | Kelebihan (% penambahbaikan) |
|||||
| Kadar Pemulihan Logam | ~9092% | Hingga 9698% | +68% hasil |
| Kehidupan Pelapik (Peringkat Utama) | 80,000 100,000 MT processed | 120,000 150,000 MT processed | +4050% Ketahanan |
| Ketersediaan Masa Beroperasi Sistem 95% 97%+ +2% Adanya |
| Specific Power Consumption Baseline 1015% reduction through optimized drive systems 1015% Penjimatan Tenaga |
| Dust Emission at Transfer Points Often requires addon bag filters Meets standards via integrated suppression Lower Capex on Dedicated Filtration |

Based on scheduled maintenance adherence.

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 50 TPH berakhir 300 Tph.
Saiz suapan: Menerima sanga ketulan sehingga 1000mm panjang tepi.
Keperluan kuasa: Total connected load typically between 250kW 800kW depending on configuration; supplied for 415V/3Phase/50Hz or as specified.
Spesifikasi Bahan: Bahagian haus utama (pelapik, rahang) manufactured from Grade III Manganese Steel or equivalent AR plate; structural frames from heavyduty ISMC/ISMB sections.
Dimensi Fizikal: Berbeza mengikut kapasiti; satu piawaian 150 TPH plant footprint is approximately 35m (L) x 22m (W) x 15m (H).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 10°C hingga +45°C; dust and weather protection standard for outdoor installation.

6. SENARIO APLIKASI

Integrated Steel Plant Slag Yard Retrofit

Cabaran:
A major steel producer faced frequent breakdowns in their aging twostage crushing setup. Metal recovery was inefficient (~88%), leading to significant value loss in aggregate stockpiles. Masa henti melebihi 15 jam setiap bulan.
Penyelesaian:
Implementation of a turnkey Slag Crusher Plant featuring a robust grizzly feeder, deepfield magnetic separators at two stages, and an automated cone crusher for secondary reduction.
Keputusan:
Pemulihan logam meningkat kepada lebih 96%. System availability reached >97%, reducing monthly downtime to under <5 jam. The recovered additional metal paid for the plant's operational costs within eight months.

Kontraktor Pemprosesan Sanga Bebas

Cabaran:
A contractor needed mobile flexibility but required higher volume than portable crushers offered. Their challenge was inconsistent feed material from multiple small steel mills.
Penyelesaian:
A semimobile Slag Crusher Plant built on modular skids with quickdisconnect electrical/utility connections was deployed.
Keputusan:
The plant could be relocated between sites within one week using conventional heavy transport. This flexibility allowed the contractor to service multiple clients without capital duplication while maintaining highvolume processing efficiency above >120 TPH consistently across varied feed materials.

7. PERTIMBANGAN KOMERSIL

Peringkat Harga: Capital cost varies significantly based on capacity and automation level.
Peringkat Kemasukan: Manual/semiautomated plants up to ~75 TPH focus on core functionality.
Standard: Loji automatik sepenuhnya (~75200 TPH), including PLC control dust suppression represent the most common investment range
Kapasiti Tinggi: Customengineered systems (>200 Tph) often include advanced monitoring systems like liner wear sensors

Ciri Pilihan & Naik taraf: Vibrating screen decks for additional product fractions; metal baler/shear for scrap processing; sistem pelinciran automatik; remote monitoring via SCADA

Pakej Perkhidmatan: Annual Maintenance Contracts (AMC), guaranteed spare parts supply agreements are available

Pilihan Pembiayaan: Equipment leasing structures are commonly offered through partner financial institutions

8.Soalan Lazim

1.Q:What if our incoming slag composition varies significantly?
A:The design incorporates adjustable crusher settings variable speed feeders allowing operators finetune throughput product size based realtime feed characteristics ensuring consistent output quality

2.Q:Apakah keperluan pemasangan biasa?
A:A level prepared base adequate electrical supply water connection dust suppression essential Detailed foundation layout drawings comprehensive utility specifications provided prior delivery facilitate smooth site preparation

3.Q:Apakah penyelenggaraan berterusan yang kita harapkan?
A.Primary maintenance involves regular inspection replacement wear parts like crusher liners conveyor belts spray nozzles Scheduled lubrication critical bearings drives Welldesigned plant provides easy safe access all service points reduce labor time

4.Q.How does this integrate with our existing material handling equipment?
A.Plants are engineered accept feed from your current loaders conveyors Output conveyors can be positioned suit your existing stockpiling loading arrangements Control systems can often interface with broader site networks

5.Q.What warranty support do you provide?
A.A standard warranty covers manufacturing defects major components typically months extended warranties available purchase Comprehensive documentation includes operation manuals parts lists recommended maintenance schedules ensure your team fully supported