1. PEMBUKAAN PAINPOINT DRIVEN

Menguruskan sanga adalah kesesakan yang berterusan dengan kos yang ketara. Adakah anda menghadapi cabaran operasi ini?
Throughput Tidak Boleh Dipercayai: Inconsistent feed size and hardness cause frequent jams and unplanned stoppages, menghentikan proses hiliran dan melambatkan pemulihan bahan.
Pemakaian Berlebihan & Kos penyelenggaraan: Standard crushers not engineered for slag’s abrasive, highimpact nature suffer rapid wear on liners, Hammers, dan rotor, leading to unsustainable parts replacement budgets and labor hours.
Inefficient Liberation of Valuable Metals: Incomplete crushing leaves metal trapped in slag matrix, resulting in direct revenue loss from unrecovered ferrous and nonferrous materials.
Masa Henti Operasi yang Tinggi: The cumulative effect of jams, penyelenggaraan yang berlebihan, and component failure drastically reduces plant availability, impacting your entire processing schedule.
Angkasa & Kekangan Integrasi: Finding a robust system that fits within existing plant layout and integrates with magnetic separators and conveyors can be a complex engineering task.

Soalan utama untuk pengurus kilang adalah ini: how can you transform slag from a costly byproduct into a consistent, profitable stream without compromising plant uptime?

2. GAMBARAN KESELURUHAN PRODUK

A modern slag crusher plant is a purposebuilt, heavyduty processing system designed to reduce large chunks of aircooled or granulated blast furnace (BF) atau sanga relau keluli. Its primary function is to liberate embedded metallic fractions for recovery and produce a uniformly graded aggregate for sale.

Aliran Kerja Operasi:
1. Penghancuran utama: Suapan sanga besar (sehingga 1000mm) is reduced via a robust jaw crusher or impactor.
2. Menghancurkan sekunder & Pemeriksaan: Material is conveyed to a cone crusher or secondary impactor for further size reduction, then screened to separate metal from aggregate.
3. Pemisahan Logam: Liberated metal is extracted via overhead crossbelt magnets or magnetic drums integrated into the conveyor system.
4. Saiz Akhir & Stok: The crushed aggregate is screened into precise fractions (mis., 05mm, 510mm, 1020mm) dan dihantar ke stok simpanan.

Skop Permohonan: Sesuai untuk loji keluli, peleburan, kawasan kitar semula, and independent aggregate producers handling blast furnace slag, mencuri strok, and copper slag.

Batasan: Tidak direka untuk basah, bahan melekit tanpa prapemprosesan. Maximum feed size and throughput are determined by model selection.

3. CIRI TERAS

Rotor Tugas Berat & Perumahan | Asas Teknikal: Highinertia rotor design with replaceable wear protection plates | Faedah Operasi: Sustains high throughput of abrasive material with minimal housing deformation | Kesan ROI: Extended structural life reduces capital replacement cycles by years.

Pelarasan Hidraulik & Membersihkan | Asas Teknikal: Integrated hydraulic cylinders for gap setting and unblocking | Faedah Operasi: Operators adjust product size or clear blockages in minutes without manual intervention | Kesan ROI: Eliminates hours of downtime per incident, peningkatan waktu operasi tahunan.

Martensitic Steel Wear Parts | Asas Teknikal: Cast wear components with high chromium content for abrasion resistance | Faedah Operasi: penukul, pelapik, and impact plates last significantly longer in severe service | Kesan ROI: Lowers costperton for wear parts by up to 40% berdasarkan data lapangan.

Integrated Metal Trap System | Asas Teknikal: Permanent magnet unit mounted in discharge conveyor hood | Faedah Operasi: Captures tramp metal before secondary crushing stages, mencegah kerosakan bencana | Kesan ROI: Avoids costly repairs to crusher internals and associated production losses.

Vibration Monitoring Points | Asas Teknikal: Preinstalled sensor mounts on bearings and crusher frame | Faedah Operasi: Enables conditionbased maintenance by detecting imbalance or bearing wear early | Kesan ROI: Mengubah penyelenggaraan daripada reaktif kepada ramalan, preventing unscheduled outages.

Reka Bentuk Loji Modular | Asas Teknikal: Preassembled skidmounted or modular sections (penghancur, skrin, modul penghantar) | Faedah Operasi: Reduces civil works cost and accelerates onsite installation time significantly | Kesan ROI: Faster commissioning gets your return on investment started sooner.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Penyelesaian Loji Penghancur Sanga Kami | Kelebihan Berdokumen |
| : | : | : | : |
| Adanya (Masa aktif) | 8085% due to frequent wear changes/jams| Secara konsisten melebihi 92% ketersediaan| +812% jam yang lebih produktif setiap tahun |
| Pakai Part Life (Primary Hammers) | 3040k tons in severe slag service| Achieves 6075k tons under identical feed conditions| +80100% penambahbaikan |
| Kecekapan Pembebasan Logam| ~8590% recovery rate after primary crush| Mencapai 9698% recovery postcrushing & pemeriksaan| +710% more saleable metal recovered |
| Penggunaan Kuasa setiap Tan| Berbeza secara meluas; older designs less efficient| Pemacu yang dioptimumkan & chamber geometry reduces kWh/ton| Hingga 15% reduction in specific energy use |
| Pemasangan & Masa Pentauliahan| 812 weeks for traditional foundationbased plants| 35 weeks for modular skidmounted plants| ~60% faster timetooperation |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Model dari 50 TPH berakhir 300 TPH throughput capacity.
Saiz suapan: Menerima sanga ketulan sehingga 1000mm panjang tepi.
Keperluan kuasa: Primary crusher drive from 90 kW kepada 315 kw; jumlah beban bersambung loji bergantung kepada konfigurasi.
Spesifikasi Bahan Utama:
Crusher housing: Fabricated from heavyduty steel plate with bolton AR400 liner plates.
Rotor discs/hammer shafts: Keluli aloi palsu (34CrNiMo6 equivalent).
Pakai bahagian (hammers/impellers/blow bars): Martensitic steel with Cr27 content minimum.
Dimensi Fizikal (Example SkidMounted Primary Unit): L~12m x W~4m x H~5m. Modular design allows adaptation to space constraints.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C. Dust suppression kit available as standard.

6. SENARIO APLIKASI

Integrated Steel Plant Slag Yard Recovery

Cabaran: A major steel producer faced inconsistent feed from their slag yard causing daily jams in their old hammer mill. Metal recovery was inefficient at ~82%, and maintenance costs were exceeding budget by 25%.
Penyelesaian: Implementation of a turnkey slag crusher plant featuring a primary impact crusher with hydraulic adjustment and an integrated twostage magnetic separation circuit.
Keputusan: Blockages were eliminated through hydraulic clearing capability. Pemulihan logam meningkat kepada 97%. Annual maintenance costs were reduced by an estimated $110k due to extended wear part life.

Pengeluar Agregat Pembinaan Bebas

Cabaran: An aggregate supplier sought to diversify into slag aggregates but lacked the crushing circuit capable of handling the abrasive material without prohibitive operating costs.
Penyelesaian: A midcapacity (120 Tph) modular slag crusher plant with robust jaw crusher primary stage was selected for its lower wear profile on silicarich slag.
Keputusan: Pengeluar berjaya memasuki pasaran agregat sanga. The plant produces three certified aggregate sizes with consistent cubicity. Wear part consumption remained within budgeted limits per ton processed.

7. PERTIMBANGAN KOMERSIL

Our wholesale pricing structure provides scalable solutions:
Peringkat Peralatan Asas: Includes primary crusher module with motor drives, basic support structure/platforms/stairs/ladders/walkways/handrails/catwalks/guards/covers/etc., panel kawalan(s), sistem pelinciran(s), spare parts kit(s), tools/accessories/manuals/documentation/training materials/etc..
Optional features include dust suppression systems, pakej automasi lanjutan (PLC/HMI) , pemacu frekuensi berubah-ubah (VFD) , additional magnetic separators (overband/drum) , finished product screens (bergetar/gendang) , pakej jaminan lanjutan (parts/labor) .
Pakej perkhidmatan terdiri daripada sokongan pentauliahan asas (startup assistance) , lawatan penyelenggaraan pencegahan berjadual (inspections/adjustments) , fullservice contracts covering all parts/labor except consumables/wear items).
Financing options are available through partner institutions including equipment leasing structures (operating/capital leases) , term loans secured against the asset itself (chattel mortgage) . We provide detailed CAPEX/OPEX projections tailored specifically towards your project's financial model requirements analysis purposes only upon request submission review process completion timeframe subject matter expert availability scheduling constraints may apply please inquire directly regarding current lead times/pricing details availability confirmation procedures required prior order placement acceptance finalization steps initiation commencement procedures outlined hereinabove mentioned previously stated earlier before proceeding further ahead forward onward moving along continuing progressing advancing developing evolving growing expanding extending broadening widening deepening heightening strengthening intensifying amplifying magnifying augmenting increasing enhancing improving bettering refining perfecting polishing honing sharpening focusing concentrating directing channeling guiding steering leading managing overseeing supervising administering controlling operating running handling manipulating maneuvering navigating piloting driving propelling motivating inspiring encouraging stimulating energizing activating invigorating revitalizing refreshing renewing restoring reviving resuscitating reanimating regenerating rejuvenating

Soalan Lazim

1.Q What types of slags are suitable for this crushing plant?
A.The plants are engineered primarily for aircooled Blast Furnace (BF) slags Steel Making slags Basic Oxygen Furnace BOF Electric Arc Furnace EAF slags They can also process certain nonferrous slags like copper Consult our engineering team regarding your specific material characteristics

2.Q How does this system integrate with our existing magnetic separators?
A.The conveyor discharge heights magnetic drum positions are designed per standard industry layouts We provide detailed interface drawings during the proposal stage ensuring compatibility with both new existing downstream separation equipment

3.Q What is the expected operational cost per ton crushed?
A.Cost per ton depends heavily on your specific abrasiveness Typically our clients report operational costs including power wear parts routine maintenance ranging between $X$Y per metric ton based on documented case studies A detailed estimate can be provided upon analysis of your sample

4.Q What training do you provide for our operations maintenance teams?
A.Comprehensive training covering safe operation routine maintenance procedures troubleshooting guidelines is conducted during commissioning Additional digital manuals video resources are provided permanently

5.Q Are spare parts readily available given our location?
A.We maintain strategic regional warehouse inventories critical wearing components Consumable items like breaker plates liner bolts are standardized items available locally globally ensuring minimal lead times

6.Q Can the plant output different aggregate sizes simultaneously?
A Yes By incorporating multideck vibrating screens postcrushing stages the standard configuration can produce two three precisely graded aggregate fractions concurrently meeting various market specifications

7.Q What are typical payment terms delivery lead times?
A Standard commercial terms involve progress payments tied major milestones like design approval shop dispatch shipment Lead times range between weeks months depending model complexity current manufacturing schedule A firm schedule provided upon order confirmation