1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Managing slag stockpiles is a persistent operational and financial drain. Сталкиваетесь ли вы с этими общими проблемами?
Unrecovered Metal Loss: Valuable ferrous and nonferrous metals trapped in slag represent direct revenue loss with every ton processed.
Inefficient Processing: Manual breaking or underpowered crushers lead to bottlenecks, limiting your plant’s overall throughput and creating storage headaches.
Высокое время простоя & Обслуживание: Frequent breakdowns from abrasive slag cause unplanned stoppages, escalating repair costs and labor hours.
Inconsistent Output Size: Poorly sized material complicates downstream handling, магнитная сепарация, and final product saleability.
Космос & Liability Constraints: Growing slag yards consume valuable real estate and present longterm environmental management concerns.

How do you transform this liability into a controlled, profitable recovery stream while ensuring system reliability? Ответ кроется в специально спроектированной установке по дроблению шлака..

2. ОБЗОР ПРОДУКТА

A slag crusher plant is a stationary or semimobile processing system designed specifically for the size reduction and liberation of metallurgical slag (доменная печь, стальная печь, медь, и т. д.). Its primary function is to crush large slag lumps into uniform, graded aggregates to maximize metal recovery via magnetic or eddy current separation.

Операционный рабочий процесс:
1. Кормить & Предварительный скрининг: Raw slag from stockpile is fed via loader; an initial grizzly screen removes fine material bypassing the primary crusher.
2. Первичное дробление: A heavyduty jaw crusher reduces large lumps (часто до 1000 мм) до приемлемого размера (приблизительно. 150200мм).
3. Вторичное дробление & Скрининг: A cone or impact crusher further reduces material, which is then screened to separate correctly sized product.
4. Разделение металлов: Sized material passes over suspended magnets or an eddy current separator to extract ferrous and nonferrous metals.
5. Накопление запасов: Cleaned aggregate is conveyed to stockpiles for sale or reuse; recovered metal is collected for recycling.

Область применения & Ограничения:
Объем: Идеально подходит для металлургических заводов, литейные заводы, плавильные заводы, and standalone metal recovery facilities processing blast furnace (лучший друг) шлак, украсть удар (ЛД-инсульт), и шлаки цветных металлов.
Ограничения: Not designed for primary rock mining or extremely highsilica content materials without specific liner configurations. Feed size must be controlled within crusher intake dimensions.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Щековая дробилка для тяжелых условий эксплуатации | Техническая основа: Губки из марганцовистой стали с оптимизированным углом захвата | Операционная выгода: Ручки большие, irregular slag lumps with high compressive force; сводит к минимуму перемычки | Воздействие на рентабельность инвестиций: Reduced primary stage blockages increase uptime by an estimated 1520%, lowering labor for manual clearing.

Устойчивые к истиранию вкладыши & Компоненты | Техническая основа: AR400/500 steel plates, replaceable wear parts in critical zones | Операционная выгода: Продлевает срок службы в высокоабразивных средах.; components are modular for easier replacement | Воздействие на рентабельность инвестиций: Полевые данные показывают 3040% reduction in liner changeout frequency compared to standard carbon steel.

Интегрированная система магнитной сепарации | Техническая основа: Overband selfcleaning electromagnet or permanent magnet positioned postcrushing | Операционная выгода: Automatically extracts liberated ferrous metal directly from the crushed material stream | Воздействие на рентабельность инвестиций: Increases pure metal recovery rates by up to 812%, turning waste into direct revenue.

Централизованная смазка & Гидравлические системы | Техническая основа: Automated lubrication points for bearings and hydraulic adjustment/tramp release on crushers | Операционная выгода: Ensures critical components are protected from dust ingress; allows quick clearing of uncrushables | Воздействие на рентабельность инвестиций: Predictive maintenance schedules reduce bearing failures by an estimated 25%, предотвращение дорогостоящего вторичного ущерба.

Vibrating Screen with Deck Options | Техническая основа: HighG multideck screen with wire mesh or polyurethane panels | Операционная выгода: Provides precise sizing of crushed aggregate for optimal market value or downstream processing | Воздействие на рентабельность инвестиций: Consistent product sizing can increase aggregate sales revenue by improving specification compliance.

Robust Structural Base Frame | Техническая основа: Fabricated steel frame with antivibration pads and reinforced supports under heavy units | Операционная выгода: Provides longterm stability under dynamic loads, reducing stress fractures and misalignment | Воздействие на рентабельность инвестиций: Minimizes foundational repairs and ensures consistent operational geometry over the plant's lifetime.

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Стандартное отраслевое решение | Наше решение для дробилки шлака | Преимущество (% Улучшение) |
| : | : | : | : |
| Скорость извлечения металлов| Standalone crusher with separate magnetic pulley| Integrated primary crushing + overband magnet + secondary separation circuit| +1015% total metal yield |
| Liner Life in Abrasive Slag| Стандартные гильзы из марганцевой стали| Multialloy composite liners & strategic wear protection design| +35% average lifespan |
| Доступность времени безотказной работы системы| Multiple standalone units with transfer points| Streamlined plant layout with reduced transfer points & централизованное управление| +8% эксплуатационная готовность |
| Потребляемая мощность на тонну| Приводы с фиксированной скоростью для всех двигателей| Configured VFDs on conveyors and secondary crusher based on load| 12% удельное энергопотребление |
| Footprint per TPH Capacity| Spreadout equipment requiring more land area| Компактный, modular design integrating feeding, сокрушительный & screening on single base frame| 20% space requirement |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Диапазон мощности: Настраивается из 50 ТПХ до 300+ Пропускная способность ТПХ.
Первичная дробилка: Jaw Crusher Model range; Feed Opening up to 1200mm x 900mm; Диапазон CSS 150250 мм.
Вторичная дробилка: Cone Crusher or Impact Crusher options based on slag hardness and desired shape.
Требования к питанию: Total installed power typically between 150kW 450kW depending on configuration (3фаза, 50/60Гц).
Основные характеристики материалов: Основной кадр (ЯВЛЯЕТСЯ 2062 конструкционная сталь), Chute/hopper liners (1012mm AR400 Steel), Конвейерные ленты (EP630/4 minimum).
Физические размеры (Типичный завод): Length ~2535m; Width ~812m; Height ~69m (без учета загрузочного бункера).
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 10°С до +45°С.; dust suppression system compliant with local regulations.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Металлургический комбинат – переработка доменного шлака

Испытание: A major steel producer faced low metal recovery from old BF slag dumps using rented mobile equipment, leading to high perton costs and inconsistent output hampering aggregate sales.
Решение: Installation of a dedicated 200 TPH stationary slag crusher plant featuring a heavyduty jaw crusher, twostage screening, and dual magnetic separation stages.
Результаты: Achieved consistent metal recovery rate of over 96%. Produced certified aggregate for road construction. Срок окупаемости достигнут менее чем за 18 months through combined metal revenue and aggregate sales.

Медеплавильный завод – шлак отражательной печи

Испытание: A smelter needed to process historically stockpiled copperrich slag fines (<30мм) that were bypassing their primary crushing circuit but still contained valuable copper matte particles.
Решение: Implementation of a specialized secondary circuit using a fine cone crusher in closed loop with screens to liberate locked copper particles before advanced separation techniques.
Результаты:Liberated an additional estimated copper content worth significant annual revenue from "waste" material previously considered uneconomical to process further.

Independent Metal Recovery Contractor

Испытание:A contractor servicing multiple small foundries required a relocatable solution that could be set up quickly on different sites without major civil works while maintaining robust performance.
Решение:Semimobile skidmounted slag crushing plant with integrated feed conveyor,магнит,and onboard power pack.All modules designed for transport on standard trailers.
Результаты:Mobilization time reduced from weeks to days.Plant demonstrated consistent performance across three different site materials within the first year,maximizing equipment utilization rates

7.КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Our approach provides clarity around investment:

• Pricing Tiers:
Base Plant(первичное дробление,магнит,базовый скрининг):Competitive entrylevel solution
Enhanced Plant(+вторичное дробление,fine screening,пылеподавление):Recommended for maximum recovery&product value
Custom Turnkey System(+feed systems,final product conveyors,силосы):Complete handling solution

• Optional Features:Dust extraction bag houses,wash systems for aggregate polishing,tramp metal detectors,belt scalesfor production weighingautomated control cabins

• Service Packages:
Годовой контракт на техническое обслуживание:Охватывает плановые проверки,смазочные материалы,и скидки на изнашиваемые детали
OnDemand Support:Flexible technical supportand field service visits
• Operator Training Programs

• Financing Options Available including leasetoown structuresand equipment financing through partners enabling capital preservation

Часто задаваемые вопросы

1 квартал:What types of slags can this plant process effectively?
А1:The plants are engineered primarily formetallurgical slags including blast furnace(лучший друг)and basic oxygen furnace(BOF/LD)slag.They can also be configuredfor nonferrous slags(медь,никель).Highly siliceous materials may require specific wear material consultation

2 квартал:What level of foundationor civil workis requiredfor installation?
А2:The modular design requiresa level compacted ground pad.A concrete foundationis strongly recommendedfor longterm stabilityof stationary plants.Semimobile skid versionsrequire minimal preparation.Detailed foundation drawingsare providedwith purchase

Q3:What kindof output sizescan we expectfromthe crushedaggregate?
A3 Output sizingis fully configurablebasedon screen deck selection.Typical product rangesinclude05mm510mm1020mmand2040mm fractions meetingmost constructionaggregate specifications

Q4 How doesyourplant handle trampmetalor uncrushablematerialthat may enterwiththe feed?
A4 The primaryjawcrusheroften includesa hydraulic toggle relief systemthat automaticallyreleases the jaws topass uncrushablematerial preventing catastrophic damage Additionallymetal detectorscanbe installedas an optionto stopthe feed beltbefore damage occurs

Q5 Whatisthe typical leadtimefrom orderto commissioning?
A5 For standardplant configurationslead timesrange between14to22weeksdependingon complexity Customturnkey projectsmay require longer Detailedproject timelinesare establishedduringthe quotation phase