Slag Crusher Plant Catalog برآمد ڪريو
1. PAINPOINT driven اوپننگ
سليگ کي منظم ڪرڻ هڪ مستقل رڪاوٽ آهي جنهن جي قابل خرچ خرچن سان. ڇا توهان انهن آپريشنل چئلينج کي منهن ڏئي رهيا آهيو?
پرائمري Crushers لاء اعلي Downtime: Abrasive slag causes premature wear on jaw plates and mantles, leading to frequent maintenance stops that halt your entire processing line.
غير موثر مواد سنڀالڻ: وڏا وڏا, irregular slag chunks from cooling beds jam feeders and conveyors, creating manual intervention points and safety hazards.
اڻ ضابطو جرمانه نسل: Using the wrong crushing technology can produce excessive, lowvalue fines instead of the optimally sized aggregate your customers demand.
ملڪيت جي اعلي ڪل قيمت: The combined expense of premature part replacement, اڻ شيڊول بند وقت, and energyinefficient processing directly erodes profit margins from your slag byproduct.
مرڪزي سوال آهي: how do you reduce this operational friction and transform slag from a disposal headache into a consistent revenue stream? The answer lies in selecting equipment engineered specifically for the task.
2. پيداوار جو جائزو
جي [ٺاهيندڙ جو نالو] Slag Crusher Plant is a heavyduty, stationary or semimobile processing system designed for the primary and secondary reduction of aircooled blast furnace (بي ايف) slag or steel slag. It is not intended for molten slag or materials with high metal content without prior separation.
The operational workflow is engineered for continuity:
1. کاڌو & پري اسڪريننگ: Slag is fed via apron feeder to a scalping screen, removing fine fractions to bypass the crusher and reduce wear.
2. پرائمري ڪرشنگ: Oversize material is directed to a robust impact crusher or jaw crusher, selected for high reduction ratio and ability to handle occasional tramp metal.
3. مواد جي منتقلي & ثانوي ڪرشنگ: Crushed material is conveyed to a secondary cone or impact crusher for precise final sizing.
4. فائنل اسڪريننگ & ذخيرو ڪرڻ: Material is classified on vibrating screens into commercial aggregate fractions (مثال, 05ايم ايم, 510ايم ايم, 1020ايم ايم) ۽ مقرر ٿيل ذخيرن تائين پهچايو.
3. بنيادي خاصيتون
هائيڊولڪ ايڊجسٽمينٽ سسٽم | ٽيڪنيڪل بنياد: Remotecontrolled hydraulic cylinders replace mechanical shims. | آپريشنل فائدا: Your operators can adjust the crusher gap setting in minutes versus hours, enabling quick response to product size requirements or clearing blockages. | ROI اثر: تائين جي ترتيبن لاءِ دير جو وقت گھٽائي ٿو 90%, پلانٽ جي دستيابي کي وڌائڻ.
Reinforced Rotor & لباس جا حصا | ٽيڪنيڪل بنياد: Highchrome martensitic steel castings with ceramic wear tiles in critical areas. | آپريشنل فائدا: Withstands extreme abrasion from slag, extending service life before replacement is required. | ROI اثر: فيلڊ ڊيٽا ڏيکاري ٿو a 4060% improvement in wear part life compared to standard manganese steel, گھٽتائي قيمت في ٽين پسائي وئي.
Integrated Metal Trap & Release | ٽيڪنيڪل بنياد: Permanent magnet overband separator coupled with an automatic release system. | آپريشنل فائدا: Continuously removes tramp metal from the crushing circuit, protecting downstream machinery from damage. | ROI اثر: Prevents costly damage to crusher internals and conveyor belts, avoiding unplanned stoppages.
مرڪزي گريسنگ & نگراني | ٽيڪنيڪل بنياد: Automated lubrication system with flow sensors connected to plant control panel. | آپريشنل فائدا: نازڪ بيئرنگ کي يقيني بڻائي ٿي ته دستي مداخلت کان سواءِ مناسب لوبريڪيشن ملي ٿي, providing early warning of potential failures. | ROI اثر: بيئرنگ سروس جي زندگي تائين وڌائي ٿو 30% and prevents catastrophic bearing seizures that cause extended downtime.
ماڊلر اسڪيڊ مائونٽ ٿيل ڊيزائن | ٽيڪنيڪل بنياد: Preassembled crusher, فيڊر, and screen modules on structural steel skids. | آپريشنل فائدا: Significantly reduces civil works and installation time on your site; جيڪڏهن ضرورت هجي ته مستقبل جي منتقلي کي آسان بڻائي. | ROI اثر: تنصيب جي قيمت تقريبن گھٽائي ٿي 25% and allows revenue generation from crushed material weeks sooner.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | اسان جي Slag Crusher پلانٽ حل | فائدو (% سڌارو) |
| : | : | : | : |
| پارٽ لائف ٽائيم لباس (پرائمري اسٽيج) | Manganese Steel Jaws/Blows Bars | HighChrome Alloy with Composite Liners | +50% |
| سراسري دستيابي (مقرر ڪيل وقت) | 8590% (due to adjustment/maintenance)| >94% (via hydraulic adjustment & نگراني) | +59% مطلق واڌارو |
| توانائي جو استعمال في ٽين پروسيس ٿيل| Fixedspeed direct drives with low load efficiency| PLCcontrolled VFD drives matching power to load demand| 15% جي طرف 20% |
| تنصيب & ڪم ڪرڻ جو وقت| 46 weeks for foundation & اسيمبلي| 1014 days for skid interconnection & ترتيب ڏيڻ| 60% |
5. ٽيڪنيڪل وضاحتون
پروسيسنگ جي صلاحيت: کان ترتيب ڏئي سگهجي ٿو 50 TPH کان مٿي 400 TPH of aircooled BF slag.
پرائمري کولہو جا اختيار: Heavyduty impact crusher (up to 1200mm feed size) or deeptoggle jaw crusher.
بجلي جي گهرج: Total installed power ranges from 150 kW کان 600 kW ترتيب تي منحصر ڪري ٿو.
اهم مواد جي وضاحت: هارڊڪس® لينر هاپرز ۽ چوٽس ۾; ST52 structural steel for frames; SEW or Nord gearboxes; SKF/FAG bearings.
جسماني طول و عرض (عام سيٽ اپ): ڊگھائي: ~35 م; ويڪر: ~ 12 م; اوچائي: ~9 م (varies per model).
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; مٽي دٻائڻ وارو نظام تيار; noise encapsulation available.
6. درخواست جا منظر
Integrated Steel Plant – Slag Aggregate Production
چيلنج: A major steel producer needed to process 250 TPH of blast furnace slag but faced weekly downtime due to wear part changes and conveyor damage from uncaptured metal.
حل: Implementation of a turnkey slag crusher plant featuring a primary impactor with hydraulic adjustment, an overband magnet at the head pulley, and modular skid design.
نتيجا: Wear part cycles extended from 6 هفتي تائين 10 هفتا. Metal removal exceeded 95%, eliminating related damage. The plant achieved an average availability of 95%, مٿان پيداوار 600,000 tons of certified construction aggregate annually.
Independent Slag Processing Contractor – Multiple Site Operations
چيلنج: A contractor servicing multiple mills required a portable solution that could be relocated every 1824 months with minimal reinstallation cost and delay.
حل: A semimobile slag crushing plant built on tripleaxle trailer modules with quickdisconnect electrical and hydraulic connections.
نتيجا: Relocation time between sites reduced from one month to under two weeks. The consistent plant performance allowed standardized maintenance schedules across all client sites, improving operational predictability.
7. تجارتي خيالات
Equipment pricing tiers are structured around throughput capacity and automation level:
بنيادي جوڙجڪ (50150 ٽي پي ايڇ): پرائمري ڪرشنگ اسٽيج شامل آهي, بنيادي اسڪريننگ, manual adjustment systems.
اصلاحي ترتيب (150300 ٽي پي ايڇ): پرائمري شامل آهن & secondary crushing stages automated metal separation PLC control system
HighCapacity Configuration (300+ ٽي پي ايڇ): Full circuit with tertiary crushing advanced dust suppression automated lubrication remote monitoring capability
Optional features include noise enclosures hot material handling packages specific wear protection alloys advanced particle shape optimization systems
Service packages are offered as annual maintenance contracts providing scheduled inspections guaranteed parts availability priority technical support Financing options include standard capital purchase finance lease agreements or tollprocessing partnerships where we operate the plant on your site
8. FAQ
1\. Is this plant suitable for processing stainless steel slag?
Our standard configuration is optimized for carbon steel BF/BOF slags For highly abrasive stainless steel slags we recommend specific metallurgy for wear parts which we provide as an option following material testing
2\. What are the expected operating costs per ton?
Based on historical data operating costs including power wear parts labor routine maintenance typically range between $0 $1 $2 per ton processed depending on local energy rates abrasiveness index of your specific slag
3\. هي سسٽم اسان جي موجوده مواد کي هٿ ڪرڻ واري سامان سان ڪيئن ضم ٿئي ٿو?
The plant is designed as a standalone node It includes feed hopper discharge conveyors can be interfaced with your existing belt systems via standardized chutework electrical connections We conduct pre installation interface reviews
4\. What training do you provide for our operations maintenance teams?
We provide comprehensive onsite training covering normal operation troubleshooting safety procedures routine maintenance tasks Documentation includes detailed operation manuals parts lists schematic diagrams
5\. What warranty period do you offer what does it cover?
We offer a standard months warranty on machinery workmanship defects extended warranties are available Critical components like crusher shafts main bearings carry specific warranty terms outlined in our commercial proposal
