Slag Crusher Plant Processing Plant Shipping
1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT
Управление шлаком является постоянным узким местом, влекущим за собой ощутимые затраты.. Сталкиваетесь ли вы с этими эксплуатационными проблемами??
Низкая пропускная способность & Высокое время простоя: Inefficient primary crushing and frequent clogging from uncrushable material halt your entire processing line, потери производственных и трудовых затрат в тысячи долларов в час.
Чрезмерный износ & Затраты на техническое обслуживание: Standard crushers rapidly deteriorate when processing highly abrasive slag, leading to premature failure of liners, молотки, and rotors. The resulting parts replacement and unplanned maintenance erode your profit margins.
Непостоянный размер конечного продукта: Poorly controlled crushing results in uneven aggregate size distribution, reducing the market value of your slag product and limiting its application in highspecification construction or cement blending.
Высокая эксплуатационная сложность & Risk: Reliance on multiple, nonintegrated units for feeding, сокрушительный, скрининг, and metal recovery increases manpower needs, угрозы безопасности, and points of potential failure.
Is your current setup delivering the reliable throughput and product quality required for profitability? Решение заключается в специально разработанном slag crusher plant processing plant.
2. ОБЗОР ПРОДУКТА
А slag crusher plant processing plant is a stationary or semimobile integrated system designed specifically for the reduction, скрининг, and separation of metallurgical slag (доменная печь, стальная печь). Он преобразует большие, irregular slag feed into precisely graded aggregates for sale or further use.
Операционный рабочий процесс:
1. Первичное получение & Предварительный скрининг: Runofpile slag is fed via loader into a robust hopper with a grizzly section to bypass fine material.
2. Начальный & Secondary Size Reduction: A heavyduty jaw crusher performs initial breaking. A secondary impactor or cone crusher then reduces the material to the target size range.
3. Скрининг материалов & Классификация: Vibrating screens separate crushed material into specified product fractions (например, 05мм, 510мм, 1020мм).
4. Восстановление металлов (Необязательный): Overband magnets or magnetic head pulleys extract remaining ferrous metal from the crushed stream for recycling revenue.
5. Накопление запасов & Отправлять: Graded aggregates are conveyed to designated stockpiles for loadout.
Область применения: Переработка доменного шлака (БФС), украсть удар (ЛД-инсульт), ферросплавный шлак, и другие неметаллические минеральные заполнители.
Ключевое ограничение: Not designed for primary rock mining or processing extremely hard virgin rock; optimal performance requires feed material within specified hardness (шкала Мооса) and size parameters.
3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ
HeavyDuty Reciprocating Plate Feeder | Техническая основа: Controlled volumetric flow with adjustable stroke | Операционная выгода: Ensures even, chokefree material delivery to the primary crusher, preventing surges and overloads | Воздействие на рентабельность инвестиций: Eliminates crusher stalls; increases overall plant throughput by up to 25% versus vibratory feeders in sticky slag conditions.
Manganese Steel Crusher Liners | Техническая основа: Workhardening austenitic manganese steel construction | Операционная выгода: Liners gain hardness upon impact, dramatically extending service life under severe abrasion | Воздействие на рентабельность инвестиций: Снижает частоту замены вкладышей на 4060%, lowering parts inventory costs and maintenance downtime.
Integrated Metal Separation System | Техническая основа: Permanent overband magnet with selfcleaning belt | Операционная выгода: Automatically recovers residual tramp metal during processing | Воздействие на рентабельность инвестиций: Generates ancillary revenue from scrap metal; protects downstream crushers from damage; improves final product purity.
Централизованная система управления ПЛК | Техническая основа: Программируемый логический контроллер с человеко-машинным интерфейсом (ЧМИ) панель | Операционная выгода: Allows singleoperator monitoring and control of entire plant flow from a protected cabin | Воздействие на рентабельность инвестиций: Reduces labor requirements; enables quick troubleshooting; provides production data for efficiency analysis.
Модульная конструкция, монтируемая на раме | Техническая основа: Preassembled structural steel skids for major components | Операционная выгода: Significantly reduces onsite civil work and installation time | Воздействие на рентабельность инвестиций: Сокращает затраты на установку примерно 30% and allows for potential relocation or plant expansion.
HeavyDuty Vibrating Screens with Deck Guards | Техническая основа: HighG force exciters and easily replaceable deck panels | Операционная выгода: Provides consistent sizing efficiency even with damp or fine slag materials; guards contain fly rock | Воздействие на рентабельность инвестиций: Ensures onspec product yield exceeding 95%, maximizing sales value; enhances operator safety.
4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА
| Метрика производительности | Отраслевой стандарт (Базовый контур дробления) | Наше решение для дробилки шлака | Преимущество (% Улучшение) |
| : | : | : | : |
| System Uptime| ~7580% (frequent stops for clearing,jams) |>92% (engineered flow control) |>15% Улучшение |
| Срок службы футеровки в дробилке первичного дробления| 6090 дни (стандартный марганец) |>180 дни (premium/workhardening) |>100% Улучшение |
| Tons Processed per ManHour| Lower due to multipoint operation |>25% higher (centralized control) |>25% Улучшение |
| Скорость извлечения металлов| Manual picking or basic magnet |>99% ferrous recovery (optimized placement) |>30% Improvement in purity/revenue |
| Установка & Время ввода в эксплуатацию| 812 недели (field assembly) |>57 недели (modular skid design) |>~40% Reduction |
5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ
Мощность обработки: Настраивается из 50 слишком 300 тонн в час (ТПХ).
Требования к питанию: Общая подключенная нагрузка обычно составляет от 150 кВт до 450 kW depending on plant configuration; supplied at 415V/50Hz or customized.
Характеристики материала: Изготовлен из конструкционной стали S355JR.; critical wear components in AR400 abrasionresistant steel and Grade I manganese steel.
Варианты первичной дробилки: Jaw Crusher sizes from 750x500mm up to 1200x1000mm feed opening.
Варианты вторичной дробилки: Ударная дробилка (for less abrasive BFS) up to Ø1400mm rotor diameter, or Cone Crusher (for highly abrasive steel slag).
Screen Specifications: Single or doubledeck vibrating screens from 1800x4800mm up to 2400x6000mm.
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 20°С до +45°С.; dust suppression spray systems are standard.
6. СЦЕНАРИИ ПРИМЕНЕНИЯ
Integrated Steel Plant – Slag Processing Yard Challenge:
A major steel producer was landfilling LD converter slag due to an inefficient old crushing circuit that produced inconsistent aggregate sizes and suffered constant hammer wear in the impactor.
Решение:
Implementation of a turnkey slag crusher plant processing plant featuring a deepchamber jaw crusher for primary reduction followed by a robust cone crusher for secondary crushing. A twostage screening system was integrated with powerful overband magnets.
Результаты:
The plant achieved a consistent product yield of over 200 TPH of highvalue aggregate sold to the local cement industry. Metal recovery increased revenue by an additional $50k annually. Planned maintenance intervals extended from monthly to quarterly.
Independent Aggregate Producer – Diversification
Испытание:
A traditional quarry operator sought to diversify into industrial byproduct processing but needed a system capable of handling highly variable feed sizes without constant reconfiguration.
Решение:
A semimobile slag crusher plant on skids with a heavyduty apron feeder was selected alongside an impact crusher with hydraulic adjustment for quick product size changes.
Результаты:
The operator could now process both purchased demolition concrete и sourced steelworks slag using one flexible unit. Changeover between materials takes less than two hours through hydraulic settings adjustments only.
7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ
Our solutions are offered across three tiers:
1. Standard Configuration Plant ($250тыс. $500 тыс.):
Includes core modules—feeder, primary jaw crusher,вибрационный экран,and conveyors—for basic sizing operations.Optional features include magnetic separator,dust suppression kit,and starter motor controls package.Service package includes commissioning plus oneyear parts warranty.
2.
3.Enhanced Recovery Plant ($500k $900k):
Adds secondary cone/impactor crushers,a multideck sizing screen,and automated metal separation systems.Optional features include finished product washing systems,tramp iron protection devices,and advanced PLC automation.Service package extends warranty coverage plus annual preventive maintenance inspections.Financing options available through partner institutions include equipment leasing plans starting at $8k/month.
4.Turnkey Processing Facility ($900к+):
Fully integrated system including receiving hoppers,surge bins,total dust collection enclosure,and automated weighloading out system.Custom engineering available.Optional features include remote monitoring via SCADA systems.Service package includes full operational training,a dedicated service manager,and guaranteed spare parts delivery within agreed terms.Comprehensive project financing can be structured based on client credit profile.
\Financing terms subject to credit approval.Please inquire directly regarding current rates.
Часто задаваемые вопросы
1.вопрос:What types of raw feed size can your standard plants accept?
А:The standard primary jaw configuration accepts feed lumps up to ~650mm edge length.Larger inlet sizes are available as an option.Precrushing may be advised if runofpile chunks exceed this dimension consistently
2.вопрос:What is the typical lead time between order placement commissioning?
A.For standard configurations lead time is typically between16and24weeks.This covers manufacturing,заводские испытания,and shipment.Modular skid design reduces site installation time significantly compared traditional builtinplace plants
3.вопрос:What ongoing maintenance does this equipment require?
A.Daily visual inspections weekly greasing checks are required.Major planned maintenance involves periodic liner replacements based actual wear rates which we help predict using historical field data.A comprehensive preventive schedule provided
4.Q.How does this integrate with our existing conveyor stockpile system?
A.The plants are designed as complete circuits but can be adapted tie into existing infrastructure.We require details regarding existing conveyor heights capacities ensure proper interface engineering during design phase
5.Q.What kind power supply needed operate typical200TPHplant?
A.A200TPHslag crushing screening circuit typically requires total connected load approximately300kW.We recommend consulting local electrical engineer ensure adequate supply transformer capacity softstart systems minimize grid disturbance
6.Q.Are spare parts readily available long after purchase?
A.All critical wear parts common consumables stocked our central warehouse.We provide recommended initial spare parts list order ensure minimal downtime guarantee availability support throughout equipment lifecycle
7.Q.What aftersales service support included?
A.All installations include commissioning supervision operator training period.We offer tiered service contracts ranging emergency breakdown support scheduled preventive maintenance visits full annual inspection programs