1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Managing slag is a persistent, costly operational bottleneck. Сталкиваетесь ли вы с этими проблемами?
High Downtime for Primary Crusher Maintenance: Frequent liner changes and unplanned breakdowns in your primary crushing circuit halt downstream processing, потери в производстве обходятся тысячами в час.
Чрезмерные затраты на изнашиваемые детали: Абразив, often unpredictable nature of slag rapidly degrades standard crusher components, leading to unsustainable consumable expenses and frequent maintenance windows.
Inefficient Liberation of Valuable Metals: Incomplete crushing leaves encapsulated metals within slag aggregates, resulting in direct revenue loss from unrecovered materials and diminished product purity.
Непостоянный размер корма & Пропускная способность: Fluctuations in slag feed size and hardness cause chokefeeding or cavitation, preventing your plant from achieving stable, designed capacity.
Высокая эксплуатационная & Safety Overheads: Manual breaking, frequent maintenance interventions, and dust generation increase labor costs and expose personnel to unnecessary risk.

Is your current solution equipped to handle the specific abrasiveness and density of slag while maximizing metal recovery and minimizing total cost of ownership?

2. ОБЗОР ПРОДУКТА: LUXURY SLAG CRUSHER PLANT

The Luxury Slag Crusher Plant is a heavyduty, stationary or semimobile crushing system engineered specifically for the primary and secondary reduction of ferrous and nonferrous slags. Он преобразует большие, irregular slag feed (до 1,5 м) into a precisely calibrated aggregate for further processing or sale.

Операционный рабочий процесс:
1. Первичное дробление: Dumpfed slag is reduced by a robust jaw crusher or gyratory crusher designed for extreme abrasion.
2. Предварительный скрининг & Восстановление металлов: Initial screening separates fines; magnetic separation extracts liberated ferrous metals at the earliest stage.
3. Вторичное дробление & Формирование: A cone crusher or impact crusher with specialized liners performs tertiary reduction for optimal particle shape.
4. Финальный показ & Классификация: Multideck screens sort output into commercial aggregate fractions (например, 05мм, 520мм, 2040мм).
5. Пылеподавление & Контроль: Integrated spray systems maintain dust levels well below regulatory thresholds throughout the process.

Область применения: Designed for integrated steel mills, медеплавильные заводы, metal recycling facilities, and standalone slag processing contractors handling blast furnace (БФС) or steelmaking slags (EAF/LD).

Ограничения: Not suitable for primary crushing of virgin rock in hightonnage mining applications where slagspecific metallurgy is not required.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Сверхмощный ротор & Дизайн камеры | Техническая основа: High inertia kinematics with wearprotected impact plates | Операционная выгода: Sustains high throughput on dense (>2.8 т/м³) slag with minimal velocity loss | Воздействие на рентабельность инвестиций: До 15% higher consistent throughput versus standard designs reduces processing time per ton.

Liner Metallurgy Package | Техническая основа: Ceramicimbedded chromium carbide overlays on critical wear zones | Операционная выгода: Increases wear life by 34x in highly abrasive silicate matrix environments | Воздействие на рентабельность инвестиций: Reduces liner change frequency by over 60%, cutting parts inventory cost and maintenance labor.

Intelligent Tramp Metal Protection | Техническая основа: Hydraulic or pneumatic release system with autoreset functionality | Операционная выгода: Prevents catastrophic damage from uncrushable metals (например, бродячая сталь) without stopping the crusher | Воздействие на рентабельность инвестиций: Eliminates costly rotor repair/replacement events and associated production losses exceeding $50k per incident.

Adaptive Crushing Logic (ACL) | Техническая основа: PLCcontrolled variable drive adjusts closedside setting (CSS) based on realtime power draw | Операционная выгода: Maintains optimal product gradation despite variations in feed hardness and slab size | Воздействие на рентабельность инвестиций: Improves yield of highvalue aggregate fractions by an average of 12%, enhancing product revenue.

Integrated Dust Containment Skirting | Техническая основа: Multistage sealing at transfer points with negative pressure zones | Операционная выгода: Contains airborne particulate at source, maintaining plant cleanliness and operator safety | Воздействие на рентабельность инвестиций: Reduces housekeeping labor by an estimated 30% and ensures continuous compliance with environmental standards.

Модульные платформы обслуживания | Техническая основа: Engineered access platforms integrated into the plant superstructure | Операционная выгода: Обеспечивает безопасность, toolready access to all service points (вкладыши, экраны, ремни) for faster maintenance | Воздействие на рентабельность инвестиций: Сокращает время планового технического обслуживания до 40%, увеличение годового рабочего времени.

Централизованная смазка & Система мониторинга| Техническая основа: Automated lubricant delivery to all major bearings with flow sensors| Операционная выгода: Ensures optimal bearing life under highload conditions and provides early failure warning| ROI Impact extends major bearing service intervals by ~25% prevents unplanned stoppages from lubrication failures

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт | Luxury Slag Crusher Plant Solution | Преимущество (% Улучшение) |
|||||
| Срок службы вкладыша (Абразивный шлак) | ~600 часов работы | ~2,200 operating hours | +267% |
| Metal Liberation Efficiency | ~8590% recovery postcrushing | ~9497% recovery postcrushing | +8% |
| Удельная потребляемая мощность | ~0.9 1.1 кВтч/тонна | ~0.75 0.85 кВтч/тонна |18% |
| Среднее время между отказами (среднее время безотказной работы) | ~450 часов |>720 часы |>+60% |
| Average Throughput Consistency ±15% from rated capacity ±5% from rated capacity |10pp variance |
| Выбросы пыли в пунктах перевалки >10 мг/м³ <5 мг/м³ |50%

5.ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Диапазон мощности: Настраивается из 150 к 600 тонн в час.
Максимальный размер подачи: До 1500 мм длина кромки.
Размеры конечного продукта: Adjustable from 05mm up to 040mm.
Primary Drive Power: От 160 кВт до 400 кВт в зависимости от конфигурации.
Crusher Frame Construction: Welded steel plate with reinforced stress zones; minimum yield strength of 355 МПа.
Wear Part Specifications: Primary breaker plates manufactured from Xwin® or equivalent ceramic composite material.
Физический след (Типичный): Approximately Length=25m x Width=12m x Height=9m for a full circuit plant.
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 20°C до +45°C, доступны дополнительные пакеты обогрева/охлаждения..

6 СЦЕНАРИИ ПРИМЕНЕНИЯ

Integrated Steel Mill – Blast Furnace Slag (БФС) Processing Challenge:

A major mill faced escalating landfill costs for BFS and needed to produce a highquality aggregate for cement substitution but struggled with rapid wear in their existing crushers causing unreliable supply contracts

Решение:

Implementation of a turnkey Luxury Slag Crusher Plant configured with primary jaw crusher ceramic liners ACL system

Результаты:

Achieved consistent production of SCMgrade aggregate Wear part costs reduced by $140k annually Secured a longterm offtake agreement based on reliable supply eliminating $80k/year in landfill fees

Copper Smelter – Recovering Residual Copper

Испытание:
A smelter’s legacy process failed to liberate fine copper trapped within granulated slag leading to an estimated $2M+ annual value loss in unrecovered metal alongside lowvalue aggregate

Решение:

Installation of a secondary/tertiary Luxury Slag Crusher Plant circuit featuring highreduction cone crushers precise screening enhanced magnetic separation

Результаты:

Copper recovery efficiency increased from %87 %96 Aggregate product value increased due cleaner mineral liberation Payback period on capital investment achieved in under months

7 КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Pricing tiers are projectspecific based on required capacity modularity level
Базовый уровень растений ( т/ч): Includes core crushing screening basic dust control
Premium Plant Tier ( т/ч): Adds ACL intelligent metal protection automated lubrication advanced dust suppression
Elite Turnkey Tier ( т/ч): Full plant design permitting modular erection commissioning training

Дополнительные функции:
Hot Slag Handling Packages
Advanced Air Classification Systems
OnBoard Weighing Analytics
Remote Monitoring Diagnostics Portal

Пакеты услуг:
Платиновая поддержка:hour onsite response guaranteed parts availability annual health audits
Золотая поддержка:hour remote support scheduled inspections parts discount
Bronze Support: Basic preventive maintenance schedule parts supply

Financing Options available include capital lease operating lease project financing terms tailored year cycles

8 Часто задаваемые вопросы

What if our slag composition varies significantly between batches?
The Adaptive Crushing Logic automatically compensates for hardness variations maintaining product consistency without manual intervention Field data shows gradation stability improves by over compared fixedsetting systems

How does this plant integrate with our existing material handling system?
Our engineering team conducts dimensional interface analysis All plants feature standardized discharge heights conveyor widths Electrical control systems are designed for integration into your existing PLC SCADA network

What is the expected operational availability?
Based on field performance data across installations designed operational availability exceeds when following prescribed maintenance protocols This factors in scheduled downtime liner changes

Легко ли доступны изнашиваемые детали??
Yes We maintain regional inventory critical wear components Furthermore our liner design utilizes longlife materials reducing change frequency Consumption rates are provided during feasibility stage accurate budgeting

Предоставляете ли вы гарантии производительности??
Yes We provide guaranteed minimum throughput maximum power consumption wear life rates key consumables These are contractually defined after review your specific slag analysis