Commercial Slag Crusher Plant Brochure
1. PAINPOINT driven اوپننگ
توهان جي اسٽيل مان سليگ کي منظم ڪرڻ, ferroalloy, or nonferrous metal production is a persistent operational bottleneck. Inefficient processing directly impacts your bottom line through high handling costs, lost revenue from unrecovered metallics, and unplanned maintenance downtime. ڇا توهان انهن چئلينجن کي منهن ڏئي رهيا آهيو?
اعلي نيڪال جي قيمت & ذميواري: Transporting and landfilling untreated slag consumes significant budget and creates longterm environmental liability.
Unrecovered Metal Loss: Ineffective crushing leaves valuable metallics locked in slag, representing direct revenue loss per ton processed.
ضرورت کان وڌيڪ بند وقت & پائڻ: Standard crushers not built for abrasive slag suffer rapid wear part failure, causing frequent, costly production stops.
غير مطابقت واري پيداوار & Bottlenecks: An undersized or illconfigured crusher creates irregular feed size for downstream screening and sorting, limiting overall plant throughput.
خلا & لاجسٽڪ پابنديون: Bulky, multistage crushing setups require excessive floor space and complicate material flow within a confined plant layout.
پلانٽ مينيجرز لاءِ مرڪزي سوال هي آهي: how can you transform slag from a cost center into a recoverable asset while ensuring relentless, lowmaintenance operation?
2. پيداوار جو جائزو
Our Commercial Slag Crusher Plant is a heavyduty, stationary processing system engineered specifically for the continuous reduction of aircooled or granulated metallurgical slag. It is designed to liberate encapsulated metal for maximum recovery and produce a consistently sized aggregate product for commercial sale.
آپريشنل ڪم فلو:
1. کاڌو & پري اسڪريننگ: Runofplant slag is fed via loader or conveyor into an integrated grizzly or scalping screen to remove fine fractions and bypass noncrushable debris.
2. پرائمري سائيز جي گھٽتائي: Oversize material is directed into the core impactor or jaw crusher module, applying high inertia to fracture slabs and liberate metallic inclusions.
3. ڌاتو جدا ڪرڻ & خارج ٿيڻ: Crushed material discharges onto a heavyduty discharge conveyor, typically passing over an overhead magnetic separator to extract liberated ferrous metal.
4. ثانوي ڪرشنگ (اختياري): For specific aggregate specifications, a secondary cone crusher module can be incorporated for precise cubical shaping.
ايپليڪيشن جو دائرو: Designed for integrated steel plants, فاؤنڊيري, ٽامي سميلٽرز, and ferroalloy producers processing blast furnace (بي ايف) سليگ, بنيادي آڪسيجن فرنس (بي او ايف) سليگ, electric arc furnace (اي ايف) سليگ, and nonferrous slags.
اهم حدون: Not designed for primary rock mining applications or processing unsorted demolition debris with excessive tramp metal. Feed size must comply with crusher opening specifications.
3. بنيادي خاصيتون
HeavyDuty روٽر & Impact System | ٽيڪنيڪل بنياد: Highinertia rotor with monolithic manganese hammers/bimetal blow bars | آپريشنل فائدا: Sustains high impact energy against abrasive slag with minimal wear rate; handles occasional tramp metal without catastrophic failure | ROI اثر: Reduces wear part change frequency by up to 40%, lowering direct parts cost and labor hours dedicated to maintenance.
هائيڊولڪ ايڊجسٽمينٽ & صاف ڪرڻ | ٽيڪنيڪل بنياد: Integrated hydraulic cylinders for apron positioning and crusher housing opening | آپريشنل فائدا: Allows operators to adjust product gradation in minutes and clear blockages safely without manual entry into the crushing chamber | ROI اثر: Eliminates hours of dangerous manual labor per blockage event; enables quick optimization for varying feed materials.
AbrasionResistant Lining System | ٽيڪنيڪل بنياد: Bolton wear liners made of AR400/500 steel in highwear zones | آپريشنل فائدا: Protects the crusher’s structural frame from abrasion, preserving its longterm integrity and preventing costly structural repairs | ROI اثر: Extends the service life of the main chassis by years, توهان جي سرمائيداري سيڙپڪاري جي حفاظت.
Integrated Grizzly Feeder | ٽيڪنيڪل بنياد: Steppededge vibrating grizzly feeder with adjustable spacing | آپريشنل فائدا: Removes subsize material before crushing (increasing effective capacity) and evenly distributes feed across full rotor width for uniform wear | ROI اثر: Increases total plant throughput by preventing chokefeeding of fines; extends wear part life through even distribution.
PLC جي بنياد تي ڪنٽرول & نگراني | ٽيڪنيڪل بنياد: Centralized control panel with PLC featuring amp draw monitoring, bearing temperature sensors, and vibration detection points | آپريشنل فائدا: Provides realtime operational data to prevent overload conditions; enables predictive maintenance scheduling based on actual load data | ROI اثر: Prevents major component failures; allows maintenance planning during scheduled stops.
Modular Base Frame Design | ٽيڪنيڪل بنياد: Preassembled crusher module mounted on a unified heavyduty support frame | آپريشنل فائدا: Simplifies foundation requirements and reduces onsite assembly time during installation; مستقبل جي ٻيهر ترتيب ڏيڻ يا منتقل ڪرڻ جي اجازت ڏئي ٿي | ROI اثر: تنصيب جي قيمت تقريبن گھٽائي ٿي 25% and minimizes plant commissioning downtime.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري حل | Our Commercial Slag Crusher Plant Solution | فائدو (% سڌارو) |
| : | : | : | : |
| ڪپڙا پارٽ لائف (بلو بار / هيمر) | Manganese Steel Castings | Proprietary BiMetal Alloy Castings / Ceramic Composite Liners Optional| +3550% ڊگهي آپريشنل زندگي |
| Metal Liberation Efficiency (Ferrous Recovery) ~90% liberation rate postcrush >95% liberation rate postcrush +57% increase in recovered metal yield |
| Throughput Consistency Under Abrasive Feed ~15% capacity drop over 100 ڪم جا ڪلاڪ <8% capacity drop over 100 ڪم جا ڪلاڪ +47% more stable output |
| Unplanned Downtime Due to Blockages Average 812 hours per month Average 50% reduction in blockagerelated stops |
| ملڪيت جي ڪل قيمت (5Year Estimate) Based on parts + محنت + downtime Based on our field data analysis Estimated 2030% هيٺيون |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 50 ختم ڪرڻ 600 ميٽرڪ ٽين في ڪلاڪ (ٽي پي ايڇ), depending on feed size and desired product specification.
بجلي جي گهرج: پرائمري ڊرائيو موٽرز کان 150 kW کان 450 ڪلواٽ; total plant power dependent on configuration (فيڊرز, پهچائيندڙ).
Feed Size Maximum: Up to 1000mm x 1200mm slab handling capability (model dependent).
Product Size Range: Adjustable from 150mm down to 40mm in primary configuration; finer sizes achievable with secondary circuit.
اهم مواد جي وضاحت: Mainframe fabrications from heavyduty steel plate; Rotor shaft forged alloy steel; Bearings rated for high shock loads; Wear components in premium manganese or chromium iron alloys.
جسماني طول و عرض (Typical Primary Module): Approximately L12m x W4m x H5m. Foundation loads provided per project.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; dust suppression system connections standard.
6. درخواست جا منظر
Integrated Steel Plant – BOF Slag Processing
Challenge A major steel producer faced escalating landfill costs for BOF slag and needed to recover contained scrap metal more efficiently. Their existing jaw crusher suffered constant liner wear and poor metal liberation.
Solution Implementation of a highinertia impactortype Commercial Slag Crusher Plant with an integrated magnetic head pulley on the discharge conveyor.
Results Metal recovery increased by 6%. The consistent 80mm output improved downstream screening efficiency by 15%. Wear part costs decreased by an estimated $18,000 annually due to longer service intervals.
Ferrochrome Smelter – Lump Slag Aggregate Production
Challenge A smelter required a reliable method to process large lumps of aircooled ferrochrome slag into a saleable construction aggregate. Throughput was limited by frequent jamming in their old compressionstyle crusher.
Solution Installation of a grizzlyfed impact crusher plant with hydraulic adjustment and clearing capabilities specifically configured for highly abrasive ferrochrome slag.
Results The plant achieved a steady throughput of 180 TPH without blockages. The hydraulic system enabled quick product size adjustments between rail ballast and road base specifications. Aggregate sales now offset over onethird of the site’s raw material handling costs.
7. تجارتي خيالات
Our Commercial Slag Crusher Plants are offered in three primary tiers:
1. معياري ڊيوٽي پلانٽ: گھٽ tonnage لاء (<150 ٽي پي ايڇ) or intermittent use applications processing less abrasive slags like some nonferrous varieties.
2. HeavyDuty Plant: Our most common configuration for continuous operation in EAF/BOF steel mills at midrange capacities (150400 ٽي پي ايڇ), featuring standard abrasion packages.
3. UltraDuty Plant: Engineered for maximum abrasion resistance (>400 ٽي پي ايڇ) in severe applications like stainless steel or highly abrasive alloy slags, featuring premium wear materials throughout.
Optional features include secondary/tertiary crushing modules automated metal sorting systems advanced dust suppression packages extended remote monitoring service contracts
Financing options are available including capital lease operating lease project financing terms tailored to match your cash flow requirements
8.FAQ
Q What are my foundation requirements?
A We provide detailed foundation drawings specific to your ordered model Our modular base frame design simplifies civil work but requires a solid reinforced concrete pad designed by your contractor based on our load data
Q How does this integrate with my existing conveyors screens?
A Our engineering team will review your current layout feed points discharge heights The crusher plant is designed with standard conveyor interfaces We can specify necessary chutes transfer points as part of the scope
Q What is the expected operational availability?
A When maintained according to our schedule field data shows operational availability exceeding92 excluding planned maintenance stops This is due primarilyto the robust designand predictive monitoring systems
Q Can you provide performance guarantees?
A Yes we offer guaranteed minimum throughput capacity based on agreed feed material specificationsand product size as well as maximum power consumption under load These are detailed in commercial proposals
Q What does the typical service package include?
A Our recommended package includes scheduled inspections remote monitoring support annual bearing grease analysisand guaranteed priority shipmentof criticalwear parts This structured approach maximizes uptime
Q How long does installation take?
A Fora standard heavy dutyplantwith preassembled modules onsite mechanical erection typically requires1014 dayswith an experienced crew Electrical connectionand commissioning add further time dependenton site readiness
