Slag Crusher Plant Distributors Design Service
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?
غير منصوبا بند وقت: معياري ڪرشرن ۾ بار بار بند ٿيڻ ۽ رگڻ وارو لباس اڻ شيڊول سار سنڀال جي اسٽاپن جو سبب بڻجي ٿو, halting downstream processing.
اعلي آپريشنل خرچ: Premature failure of crusher liners, هٿيار, and screens under highimpact, abrasive conditions drives up your parts inventory and labor expenses.
غير مطابقت رکندڙ ذريعي & پيداوار جي ماپ: Variable slag feed size and composition result in uneven product gradation, complicitating material handling and reducing the value of your processed aggregate.
وڌ ۾ وڌ فائنس پيدا ڪرڻ: Inefficient crushing action creates more fine particulate than required for your market, wasting potential product and creating dust control issues.
Is your current equipment causing profit erosion through maintenance costs and lost production time? A purposeengineered solution is required to transform this industrial byproduct into a consistent revenue stream.
2. پيداوار جو جائزو: SLAG CRUSHER PLANT
اي Slag Crusher Plant is a stationary or semimobile processing system specifically engineered to reduce large chunks of aircooled or granulated metallurgical slag (blast furnace, اسٽيل فرنس) into precisely graded aggregate for construction, روڊ جو بنياد, or raw feed for cement manufacturing.
آپريشنل ڪم فلو:
1. ابتدائي گھٽتائي: وڏي سليگ فيڊ (1000mm تائين) is introduced to a heavyduty jaw crusher or impact breaker for initial size reduction.
2. ثانوي ڪرشنگ & اسڪريننگ: Material is conveyed to a cone crusher or secondary impactor for further refinement, then passed over a vibrating screen to separate onspec product.
3. Oversize Recirculation: Oversized material is recirculated via return conveyors back into the secondary crusher in a closedloop system.
4. آخري ماپ & ذخيرو ڪرڻ: Correctly sized material is routed through final screening decks and conveyed to designated stockpiles for loadout.
ايپليڪيشن جو دائرو: Processing blast furnace slag (BFS), اسٽروڪ چوري ڪرڻ (LD slag), ferroalloy slag, and other nonmetallic mineral aggregates. Designed for integrated mill sites, standalone recycling yards, and aggregate producers.
اهم حدون: Not designed for primary ore processing or extremely wet, sticky materials without preprocessing. Feed size must be controlled within plant design limits.
3. بنيادي خاصيتون
HeavyDuty Vibrating Grizzly Feeder | ٽيڪنيڪل بنياد: Controlled feed rate with prescreening | آپريشنل فائدا: Removes fine fractions before primary crushing, reduces unnecessary wear and improves primary crusher efficiency | ROI اثر: Extends liner life in primary stage by an estimated 1520%, lowering parts cost per ton
Manganese Steel Wear Package | ٽيڪنيڪل بنياد: Austenitic manganese steel workhardens under impact | آپريشنل فائدا: ڪَرَڻَ جو جهوڙو, مقدر, ڪپڙا, and impact hammers develop a hardened surface layer in service, resisting abrasive wear from slag | ROI اثر: Documented increase of 3050% in wear life compared to standard AR steel components
Impact Crusher with Hydraulic Adjustment | ٽيڪنيڪل بنياد: Dynamic impact crushing with adjustable aprons/grinding path | آپريشنل فائدا: Operators can finetune product gradation without shutdowns; hydraulic opening assists in clearing blockages from tramp metal | ROI اثر: تائين جي پراڊڪٽ جي تبديلين لاءِ ڊائون ٽائم گھٽائي ٿو 80% and minimizes stallrelated maintenance
Reinforced Plate Conveyors with AbrasionResistant Liners | ٽيڪنيڪل بنياد: Hightensile belts with vulcanized splices and replaceable skirting/wear liners | آپريشنل فائدا: Withstands continuous abrasion from sharp slag edges, minimizing belt tears and spillage | ROI اثر: Lowers conveyor maintenance costs and improves plant housekeeping/safety
مرڪزي گريسنگ & مٽي کي دٻائڻ وارو نظام | ٽيڪنيڪل بنياد: Automated lubrication points and strategically placed fog cannons/nozzles | آپريشنل فائدا: نازڪ بيئرنگ کي يقيني بڻائي ٿي ته مناسب سڻڪ حاصل ڪن; suppresses dust at transfer points for compliance and operator health | ROI اثر: برداشت جي ناڪامي کي روڪي ٿو (a leading cause of unplanned stops) and reduces water consumption vs. manual spraying
PLCBased Control Panel with Motor Protection | ٽيڪنيڪل بنياد: Programmable Logic Controller monitoring amp draw, گرمي پد, and sequence interlocking | آپريشنل فائدا: Provides operators with clear fault diagnostics, prevents incorrect startup sequences, and protects motors from overloads | ROI اثر: Simplifies troubleshooting by 40%, protecting major electrical components from catastrophic failure
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري حل | اسان جي Slag Crusher پلانٽ حل | فائدو (% سڌارو) |
| : | : | : | : |
| لائنر زندگي (پرائمري اسٽيج)| Standard AR400 Liners | WorkHardening Manganese Steel Liners w/ Optimal Geometry | +35% Longer Life |
| Tramp Metal Incident Resolution Time| Manual clearing requiring partial disassembly / oxycutting| Hydraulic Opening System & Access Doors for NonFerrous Metal Release| 90% Downtime per Incident |
| مجموعي طور تي پلانٽ جي دستيابي| ~8285% (شيڊول ٿيل & Unscheduled Stops) |>92% (via redundant drives, easyaccess maintenance design)| +810% Absolute Increase |
| Power Consumption per Ton Processed| Fixedspeed drives across all units| PLCcontrolled VFDs on conveyors & fans; highefficiency crusher motors| 12% توانائي جو استعمال |
| پيداوار جي درجه بندي مطابقت (± spec)| ±15% variability due to wear & manual adjustment| ±5% via hydraulic crusher adjustment & prescreening feeder control| +66% More Consistent Output |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 50 TPH کان مٿي 400 TPH processed slag.
پرائمري کولہو جا اختيار: جهيڙيندڙ (900mm x 600mm to 1500mm x 1200mm) or Primary Impact Crusher (Φ1250mm x 1500mm to Φ2000mm x 2500mm rotor).
ثانوي/Tertiary کولہو جا اختيار: مخروطي ڪرشرز (HP200 HP500 equivalent) or Secondary/Tertiary Impact Crushers.
بجلي جي گهرج: ڪل ڳنڍيل لوڊ کان 150 kW کان 800 kW ترتيب تي منحصر ڪري ٿو; supplied for 400V/50Hz or other international standards.
اهم مواد جي وضاحت: Primary frame construction from S355JR structural steel; wear surfaces lined with AR400 or Hardox 450; crushing chambers with Mn18Cr2 or equivalent manganese steel.
جسماني طول و عرض (Typical SkidMounted Unit): Length ~25m – 45m; Width ~6m – 8m; Height ~7m –10m.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; مٽي جي اخراج تي ڪنٽرول <20 mg/Nm³ at outlet with suppression system active.
6. درخواست جا منظر
Integrated Steel Mill Recycling Yard
چيلنج: A major steel producer needed to process variablesized steel slag (LD slag) containing occasional tramp metal. Their existing plant suffered weekly breakdowns due to crusher jams and extreme abrasion wear.
حل: Implementation of a turnkey Slag Crusher Plant featuring a heavyduty apron feeder for scalpings, a primary impact crusher with hydraulic assist hoods, magnetic separation at key stages, and manganese steel wear parts throughout the crushing circuit.
نتيجا: ٻوٽن جي دستيابي کان وڌي وئي 78% جي طرف 94%. Tramp metal incidents now resolved in under 30 minutes versus previous 8hour shifts. Aggregate output met railway ballast specifications consistently.
Independent Construction Aggregate Producer
چيلنج: An aggregate supplier processing purchased blast furnace slag faced high fines generation (>25%) using older jawandcone technology, reducing the volume of valuable coarse aggregate.
حل: A tailored twostage Slag Crusher Plant utilizing a jaw crusher for primary reduction followed by a cone crusher in closed circuit with a tripledeck screen. The chokefed cone setup was optimized for slabby product shape correction.
نتيجا: Fines generation reduced to below 15%, increasing saleable coarse aggregate yield by over 10%. The consistent cubical product commanded a $2/ton price premium in the local readymix concrete market.
Cement Plant Raw Feed Preparation
چيلنج: A cement manufacturer using granulated blast furnace slag as an additive needed precise <10mm sizing but sought lower power costs than their existing hammer mill system offered.
حل: Installation of our Slag Crushing Plant configured around highefficiency vertical shaft impactor technology specifically tuned for granulated material.
نتيجا: Achieved required sizing at 22% lower specific power consumption while reducing noise levels significantly within the plant boundary.
Commercial Considerations Equipment Pricing Tiers:
Base Configuration SkidMounted Plant includes primary secondary crushing basic screening starting at Tier I pricing
MidRange Configuration adds automated magnetic separator dust suppression system PLC controls
Premium Turnkey Configuration includes full enclosure climate control advanced vibration monitoring remote support connectivity
اختياري خاصيتون:
Portable wheelmounted chassis
Advanced metal detection rejection systems
Sound attenuation enclosures
Automated sampler systems
Spare parts starter kits
سروس پيڪيجز:
Standard Warranty covers parts defects
Extended Service Plan includes annual inspection labor discounts
Full Maintenance Contract providing fixedcost coverage all scheduled unscheduled maintenance
فنانسنگ جا اختيار:
Capital equipment financing available through partners leasepurchase agreements operating leases terms years
FAQ Q1 Is your Slag Crrusherr Plannt compatible witth our existing conveyorr feederr systemms?
A Engineering review can ensure interface compatibility We designeed hopper heights discharge chutes conveyor speeds integrate witth client site layout Belt widths capacities are matched during proposal stage
Q2 Whatt iis thee typical installation commissioning timeline?
A Forr skidded modules onsite erection mechanical electrical hookup typically requires weeks following foundation preparation Commissioning performance testing takes additional week
Q3 How does this plantt handle wettt oor sticky slagg?
A While designed primarily foor aircooledd slagg grizzly feeders can bypass fines Forr materials witth higgh moisture content we recommend predryingr adding heating elements tto hoppers prevent bridging Additional cost option
Q4 Whatt aree thee critical spare partts we should stock onsite?
A We provide recommended spares list basedd onn expected wear rates Typically includes set off primary jaw dies set off secondary concave mantles key conveyor idlers stock off screen meshes
Q5 Can you provide performance guarantees?
A Yes We offer guaranteed throughput capacity rated power consumption basedd onn agreed feed material analysis Product gradation curves are also guaranteed forn given CSS settings
Q6 Do you offer operator training?
A Comprehensive training forn client operators maintenance staff iss included witth every installation Covers daily operation routine maintenance troubleshooting safety procedures
Q7 Whatt iis thee expected lifespan off thee plantt structure major components?
A The main plant structure has design life exceeding years witth proper upkeep Major crushers frames have similar lifespan Highwear components like liners hammers are consumables replaced per usage cycles defined inn operation manual
