Iso Certified Slag Crusher Plant Quotation
ISO Certified Slag Crusher Plant: Engineered for Maximum Uptime and Material Recovery
1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT
Managing slag byproduct is a persistent operational challenge with direct cost implications. Вы испытываете:
Чрезмерное время простоя: Частая смена вкладышей, засоры, and mechanical failures halting your processing line for hours, costing thousands in lost production per event?
Unpredictable Operating Costs: Spiking maintenance bills from abrasive slag wear on substandard components and high energy consumption from inefficient crushing action?
Непостоянное качество продукции: Variable output gradation leading to poor sales value for your aggregate or difficulties in downstream recycling processes?
Регуляторный & Риски безопасности: Dust emissions exceeding limits and manual handling of uncrushed material creating compliance issues and workplace hazards?
These challenges erode profitability. Основной вопрос: how can you transform slag from a costly waste stream into a consistent, revenuegenerating product with predictable operating expenses? The answer lies in purposebuilt, precisionengineered crushing technology.
2. ОБЗОР ПРОДУКТА
An ISO Certified Slag Crusher Plant is a stationary or semimobile crushing circuit specifically configured to process metallurgical slag (доменная печь, стальная печь, и т. д.). В его дизайне приоритет отдается долговечности., последовательный вывод, и контроль пыли.
Операционный рабочий процесс:
1. Кормить & Предварительный скрининг: Runoffurnace slag is fed via loader. An optional grizzly or prescalper removes fine fractions and noncrushable debris.
2. Первичное уменьшение размера: Мощная щековая дробилка или ударный молоток выполняют первоначальное дробление., reducing large slabs to manageable size.
3. вторичный & Третичное дробление: Cone crushers or further impact crushers refine the material to the desired specification, ensuring cubical product shape.
4. Размеры & Накопление запасов: Vibrating screens classify the crushed slag into precise fractions (например, 05мм, 510мм, 1020мм), which are then conveyed to designated stockpiles.
Область применения: Идеально подходит для металлургических заводов, standalone smelters, и специализированные площадки по переработке шлаков черных и цветных металлов..
Ограничения: Not designed for primary rock mining or processing extremely hard, abrasive igneous rocks without specific configuration adjustments.
3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ
Сверхмощный ротор & Ударные элементы | Техническая основа: Highinertia rotor design with martensitic chromium blow bars | Операционная выгода: Sustained crushing force with superior wear life in highly abrasive conditions | Воздействие на рентабельность инвестиций: Reduces blow bar change frequency by up to 40%, lowering parts inventory costs and labor hours.
Интегрированная система пылеподавления | Техническая основа: Strategically placed spray nozzles with solenoid control and water recycling | Операционная выгода: Effectively suppresses dust at feed points and transfer stations, maintaining airborne particulate below regulatory thresholds | Воздействие на рентабельность инвестиций: Mitigates risk of regulatory fines and improves site working conditions, reducing healthrelated absenteeism.
Гидравлическая регулировка & Клиринг | Техническая основа: PLCcontrolled hydraulic cylinders for crusher gap setting and tramp metal release | Операционная выгода: Allows operators to adjust product size or clear a cavity blockage in minutes without manual intervention | Воздействие на рентабельность инвестиций: Minimizes unplanned downtime; field data shows a typical clearing event is reduced from 23 часов меньше 15 минуты.
Reinforced Modular Frame | Техническая основа: Fabricated steel construction with extra reinforcement at highstress points as per finite element analysis (ВЭД) | Операционная выгода: Обеспечивает исключительную стабильность при циклических нагрузках., eliminating frame fatigue cracks common in standard plants | Воздействие на рентабельность инвестиций: Extends structural life of the plant beyond 15 годы, защита ваших капиталовложений.
Централизованная смазка & Мониторинг | Техническая основа: Automated lubrication system with flow sensors for all major bearings | Операционная выгода: Ensures optimal bearing lubrication without manual greasing, предотвращение преждевременного выхода подшипников из строя | Воздействие на рентабельность инвестиций: Отраслевые испытания демонстрируют прямую корреляцию с 60% reduction in bearingrelated breakdowns.
Высокоэффективная система привода | Техническая основа: Direct Vbelt drives or fluid couplings matched to crusher duty cycles | Операционная выгода: Minimizes power transmission losses and protects the motor from shock loads | Воздействие на рентабельность инвестиций: Delivers measurable energy savings of 812% compared to less optimized systems.
4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА
| Метрика производительности | Стандартное отраслевое решение | Сертифицированное по ISO решение для установки по дроблению шлака | Преимущество (% Улучшение) |
| : | : | : | : |
| Износ части срока службы (Ударные стержни/молотки)| На основе стандартной марганцовистой стали| Proprietary alloy/composite materials| +35% к +50% |
| Планируемый интервал технического обслуживания| Каждый 250300 часы работы| Extended to 400+ часы работы| +33% longer runtime |
| Контроль выбросов пыли| Basic bag filters or manual spraying| Integrated suppression with particle monitoring| >70% reduction in ambient dust |
| Average Product Yield (Target Fraction)| ~85% yield due to oversize/undersize| >92% yield via precise screening/crushing loop| +8% более продаваемый продукт |
| Total Energy Consumption per Tonne| Базовый уровень (100%)| Оптимизированные диски & эффективные камеры дробления| 10% снижение |
5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ
Диапазон мощности: Настраивается из 50 TPH превышает 300 ТПХ.
Требования к питанию: Общая подключенная нагрузка от 150 кВт до 600 кВт в зависимости от конфигурации; standard supply 415V/50Hz/3Phase or customizable.
Характеристики материала: Feed size up to 800mm; final product range from 40mm down to 05mm sand. Crusher liners available in Mn18Cr2, HiChrome, или керамический композит.
Физические размеры (Типичная установка): Длина ок.. 25m x Width approx. 8m x Height approx. 6м (varies with conveyor design).
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 20°С до +45°С.; dust suppression system effective up to wind speeds of 7 РС.
6. СЦЕНАРИИ ПРИМЕНЕНИЯ
Integrated Steel Plant Slag Processing Yard
Challenge A major steel producer faced inconsistent feed from stockpiled slag causing frequent jams in their old hammer mill system, resulting in weekly downtime averaging 8 часы.
Solution Implementation of a primary jaw crusher followed by a secondary cone crusher plant with heavyduty apron feeder for regulated infeed.
Results Achieved continuous operation over two shifts without blockage; plant availability increased from 82% к 96%. The consistent 20mm aggregate produced opened new sales channels in road base construction.
Copper Smelter Slag Recycling
Challenge A smelter needed to liberate entrapped metal from granulated copper slag while controlling silica dust during crushing—a major respiratory hazard.
Solution Deployment of an impact crusher plant with sealed housing and negative pressure dust extraction system feeding directly into magnetic separators.
Results Metal recovery efficiency improved by 15% due to better liberation; respirable dust levels were maintained below 1 mg/m³ consistently meeting stringent occupational health standards.
7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ
Наши сертифицированные по ISO установки для дробления шлака предлагаются в трех основных уровнях.:
1.
2.Стандартный уровень конфигурации: Включает в себя стержневые дробильные установки (jaw/impact/cone), basic structure conveyors motors starters Designed for straightforward applications Offers competitive capital cost entry point
3.Оптимизированный уровень производительности: Adds integrated dust suppression automated greasing hydraulic adjustment advanced electrical controls PLC monitoring Provides the optimal balance of performance features suitable for most high volume operations
4.Полностью индивидуальный уровень: Engineered site specific layouts special wear materials alternative drive options comprehensive sound enclosures remote monitoring connectivity For maximum process integration
Optional Features include metal detectors magnetic head pulleys wash systems for salt removal automated sampling stations
Доступные пакеты услуг:
Annual Maintenance Contracts covering scheduled inspections parts discounts priority support
Operator Training Programs conducted onsite
Financing Options include conventional leasing operating leases pay per tonne models subject
8.Часто задаваемые вопросы
What types of slag are most suitable for this plant? The plant is engineered primarily for ferrous slags blast furnace BOF steel furnace It can also process non ferrous slags like copper nickel but may require liner material specification review
How does the ISO certification benefit me as an operator? ISO certification specifically ISO9001 provides documented assurance that the plant was designed manufactured tested using rigorous quality management processes This translates directly into higher reliability consistent performance accurate technical documentation
Can we use our existing feeders conveyors screens with your new crusher plant? Yes integration studies can be conducted Our engineering team will review your current layout equipment specifications provide interface drawings ensure compatibility often resulting significant savings
What is the expected payback period on this investment? Payback periods vary based on throughput material value local aggregate pricing Typically plants processing over tonnes annually achieve payback through reduced downtime lower maintenance costs increased product sales within months
Вы осуществляете шеф-монтаж и пуско-наладку?? Yes we offer comprehensive project management services including foundation drawings mechanical electrical installation supervision final commissioning operator training ensure smooth handover