Slag Crusher Plant Fabricator
1. PAINPOINT driven اوپننگ
ڇا توهان جي سليگ هينڊلنگ آپريشن هڪ مسلسل رڪاوٽ ۽ پوشیدہ خرچن جو هڪ ذريعو آهي? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, ميٽالرجيڪل سليگ جي پروسيسنگ جا چئلينج گھڻ رخا آهن. ڇا توهان تجربو ڪري رهيا آهيو:
ضرورت کان وڌيڪ بند وقت: بار بار بند ٿيڻ, پلنگ, and abrasive wear in primary crushing stages halting your entire material recovery line?
غير متوقع ذريعي: Inconsistent feed size and composition from ladles leading to capacity fluctuations and missed processing targets?
اعلي آپريشنل خرچ: Premature failure of crusher components not designed for extreme abrasion, coupled with high energy consumption per ton processed?
Recovery Inefficiency: Inadequate liberation of metallic fractions from the slag matrix, leaving valuable material in your waste stream and reducing overall plant revenue?
حفاظت & Maintenance Burdens: Laborintensive clearing of jams and the risks associated with manual handling of large, irregular slag pieces?
اهي مسئلا سڌو سنئون توهان جي هيٺئين لائن کي گم ٿيل پيداوار ذريعي متاثر ڪن ٿا, increased maintenance labor, and suboptimal metal recovery. بنيادي سوال آهي: توهان ڪيئن قابل اعتماد حاصل ڪري سگهو ٿا, highvolume slag reduction with predictable operating costs?
2. پيداوار جو جائزو: SLAG Crusher پلانٽ
A Slag Crusher Plant is a purposebuilt, اسٽيشنري يا سيمي موبائيل پروسيسنگ سسٽم پرائمري لاءِ انجنيئر ٿيل, ثانوي, and sometimes tertiary reduction of aircooled or granulated metallurgical slag. Its function is to liberate entrapped metal (ferrous and nonferrous) from the slag matrix and produce a consistently sized aggregate for sale or further processing.
آپريشنل ڪم فلو:
1. کاڌو & پري اسڪريننگ: Runoffurnace slag is fed via loader or conveyor into a robust grizzly or scalping screen to remove fine material (30ايم ايم) bypassing the primary crusher.
2. پرائمري ڪرشنگ: Oversize material (+30mm to +500mm) enters a heavyduty jaw crusher or impact breaker designed to handle extreme shock loads and abrasion.
3. ڌاتو جدا ڪرڻ & ثانوي ڪرشنگ: The crushed product is conveyed past an overhead magnetic separator to extract liberated ferrous metal. Remaining material may pass through a secondary cone or impact crusher for final sizing.
4. آخري ماپ & ذخيرو ڪرڻ: Material is screened into specified aggregate fractions (مثال, 05ايم ايم, 510ايم ايم, 1020ايم ايم) vibrating screens ذريعي ۽ ذخيري تائين پهچايو ويو.
ايپليڪيشن جو دائرو & حدون:
دائرو: مربوط اسٽيل پلانٽس لاءِ مثالي, ٽامي سميلٽرز, ferroalloy پيدا ڪندڙ, ۽ اسٽينڊل سليگ پروسيسنگ يارڊز هٿ ڪرڻ واري ڌماڪي واري فرنس (بي ايف), بنيادي آڪسيجن فرنس (بي او ايف), برقي آرڪ فرنس (اي ايف), ladle, ۽ nonferrous slags.
حدون: Not designed for primary rock mining applications. Performance on extremely sticky or highmoisture slags may require predrying or specialized feed systems.
3. بنيادي خاصيتون
HeavyDuty پرائمري کولہو | ٽيڪنيڪل بنياد: هاء مينگانيز اسٽيل جاز & مضبوط فريم | آپريشنل فائدا: Sustained performance under extreme shock loads from large, irregular slag pieces with minimal deformation | ROI اثر: Reduces unplanned crusher downtime by up to 40% and extends jaw life by over 60% معياري ڊيزائن جي مقابلي ۾.
مربوط مقناطيسي علحدگي سرڪٽ | ٽيڪنيڪل بنياد: Overband SelfCleaning Electromagnets positioned at optimal discharge points | آپريشنل فائدا: لڳاتار, automated recovery of liberated ferrous metal directly from the crushed stream without manual intervention | ROI اثر: پاران دھات جي وصولي جي شرح وڌائي ٿي 1525%, creating a direct revenue stream from what was previously waste.
AbrasionResistant مواد جي وهڪري جو نظام | ٽيڪنيڪل بنياد: AR400/500 اسٽيل لائنر هاپر ۾, پوي ٿو, and skirts; impact beds on conveyor load zones | آپريشنل فائدا: Dramatically reduces wearrelated failures in highimpact areas, maintaining consistent flow geometry | ROI اثر: سراسري طور تي سالياني لائنر متبادل جي قيمت گھٽائي ٿي 35% and reduces conveyor belt damage.
مرڪزي PLC آٽوميشن & نگراني | ٽيڪنيڪل بنياد: Programmable Logic Controller with HMI touchscreen for system control; motor current sensors and bearing temperature monitors | آپريشنل فائدا: Enables oneoperator control of the entire plant with realtime alerts for abnormal conditions like overloads or blockages | ROI اثر: Optimizes power consumption per ton by up to 20% through controlled sequencing; reduces required operational manpower.
ماڊلر اسڪيڊ مائونٽ ٿيل ڊيزائن (اختياري) | ٽيڪنيڪل بنياد: Preassembled crusher modules on heavyduty structural skids with integrated walkways | آپريشنل فائدا: Significantly reduces civil works requirements and onsite installation time by up to 70% | ROI اثر: تيز ڪم ڪرڻ وقت جي آمدني کي تيز ڪري ٿو; facilitates future relocation if site requirements change.
Dedicated Slag Crusher Plant Dust Suppression System | ٽيڪنيڪل بنياد: Nozzle arrays at transfer points connected to a highpressure pump unit with moisture sensors | آپريشنل فائدا: Effectively controls fugitive dust at source without overwetting material which can cause downstream handling issues | ROI اثر: Ensures compliance with site environmental standards; protects other machinery from abrasive dust ingress.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري حل | This Slag Crusher Plant Solution | فائدو (% سڌارو) |
| : | : | : | : |
| دستيابي / اپٽائم| ~7580%, frequent jamming/clogging incidents| >92%, engineered feed system & ڪرشنگ چيمبر ڊيزائن| +15% آپريشنل دستيابي|
| لباس جي قيمت في ٽون پروسيس ٿيل| اعلي variability; frequent liner/impeller changes| Predictable cost; extendedlife components documented| 35% سراسري گهٽتائي|
| ڌاتو جي بحالي جي ڪارڪردگي (%)| Manual picking postcrushing or singlestage magnetic separation| Multistage liberation with optimized magnetic separation points| +20% ferrous recovery yield|
| توانائي جو واھپو (kWh/ٽن)| Often overlooked; oversized motors running constantly| PLCcontrolled optimized start/stop sequences & فيڊرز تي VFDs| 18% سراسري گهٽتائي|
| تنصيب / ڪم ڪرڻ جو وقت| Extensive field fabrication & ترتيب ڏيڻ (1216 هفتا)| Pretested modular skids requiring connection only (68 هفتا)| 50% site construction time|
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 50 TPH کان مٿي 300 TPH of processed slag.
پرائمري کولہو جا اختيار: جهيڙيندڙ (900 x 600mm to 1500 x 1200mm) or Primary Impact Crusher with hydraulic adjustment.
بجلي جي گهرج: ڪل ڳنڍيل لوڊ عام طور تي وچ ۾ 250 kW - 800 kW ترتيب تي منحصر ڪري ٿو; 415V/3Phase/50Hz لاءِ فراهم ڪئي وئي يا جيئن بيان ڪيل.
اهم مواد جي وضاحت:
Crusher Jaws/Hammers/Blow Bars: پريميئم مينگنيز اسٽيل (1822% من).
Liners/Chutes/Wear Plates: Minimum AR400 Steel.
Structural Frames & اسڪيڊس: HeavyDuty Pentaplate / IS2062 E350 Grade Steel.
Conveyor Belting: Minimum EP630/4 rated for abrasion resistance.
جسماني طول و عرض (Typical Modular Plant): Length ~40m x Width ~12m x Height ~9m (فيڊ هاپر کان سواء).
ماحولياتي آپريٽنگ رينج: 10 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; dust suppression system maintains operation within PM10 emission standards.
6. درخواست جا منظر
انٽيگريٽيڊ اسٽيل پلانٽ - BOF سليگ پروسيسنگ
چيلنج: A major steel producer faced severe bridging in their existing crusher feed hopper when processing large BOF slag lumps (>800ايم ايم), روزاني بند ٿيڻ جو سبب. Metal recovery was inefficient using a single magnet after crushing.
حل: Implementation of a custom Slag Crusher Plant featuring a vibrating grizzly feeder with stepped grizzly bars to break bridges ahead of a deepchambered jaw crusher. Two overband magnets were installed—one precrusher for loose metallics and one postprimarycrusher.
نتيجا: Bridging incidents eliminated entirely. ٻوٽن جي دستيابي کان وڌي وئي 78% جي طرف >94%. Ferrous metal recovery improved by 22%, paying back the system’s capital cost in under two years through recovered metal value alone.
آزاد سليگ پروسيسنگ ٺيڪيدار
چيلنج: A contractor servicing multiple smalltomedium EAF mills needed a portable solution that could be relocated between sites every 1824 months but required consistent high throughput without lengthy setup times.
حل: A fully skidmounted Slag Crusher Plant was supplied on four modular sections (feed module with scalper, primary crusher module, screening/magnet module). All modules featured quickdisconnect electrical/pneumatic connections.
نتيجا: Relocation time between sites reduced from three months to four weeks due to minimal civil work required at new locations. Consistent throughput of ~120 TPH maintained across different site configurations.
7. تجارتي خيالات
Our Slag Crusher Plants are offered in three primary tiers based on capacity and automation level:
1. معياري ڊيوٽي پلانٽ (<100 ٽي پي ايڇ): Focuses on core reliability with essential features like primary crushing and magnetic separation—ideal for smaller operations prioritizing capital efficiency.
2. HeavyDuty پلانٽ (100 - .200 ٽي پي ايڇ):) Our most common configuration includes full abrasion protection package advanced PLC automation multistage sizing/screening—designed for maximum total costofownership savings in continuous operation
3.
4.HighCapacity/Turnkey System (>200 ٽي پي ايڇ):) Includes all heavyduty features plus optional secondary crushing stage automated sampler complete dust collection baghouse system project management services
اختياري خاصيتون شامل آهن:
خودڪار گريس لوڻ وارو نظام
Thermal camera monitoring for bearings
Advanced aggregate cubicity shaping kit
Onboard diesel generator power pack
Service Packages range from basic commissioning/spare parts supply upto comprehensive annual maintenance contracts including scheduled wear part replacement
Financing options including equipment leasing rentalpurchase agreements are available subjecttoqualification providing flexibilityincapitalexpenditureplanning
8.FAQ:
Q1 How do I determine if my specific typeofslag requiresajawcrushersoranimpactcrushersastheprimaryunitintheslagcrushersplants?
A1 The choice dependsonslag characteristics Jaw crushers are generally preferredforhighlyabrasive dense slagswithcompressivestrengthlikeaircooledBFslag duetotheirdirectforceandslowerspeed minimizing wear Impactors can offer higher reduction ratiosandbetter particle shapeforlessabrasive slags like someEAFslag We analyze your samplematerialin our labtoprovideadatabacked recommendation
Q2 Whatisthetypicalinstallationfootprintandfoundationrequirementsforaskidmountedslagcrushersplants?
A2 While significantly reduced comparedtotraditional plants level compacted groundoraminimalconcretethicknesspadissufficientforskid placement Major civil workislimitedtofeedhopperpitsandfinalproducttunnelconveyors if applicable Detailed foundation drawings are providedforsitepreparation
Q3 CananexistingslagcrushersplantsbeupgradedwithyourkeyfeaturesliketheenhancedmagneticcircuitorPLCautomations?
A3 Yes many components suchasoverbandmagnets advancedlinersandcontrol systems can be retrofitted ontoexistinginfrastructure Our engineers can conductanauditofyourcurrentsetupandproposephasedupgradestoimproveperformanceandROI
Q4 Howdoyouquantifythepotentialmetalrecoveryimprovementbeforepurchases?
A5 We conductarepresentativesampletestingprograminvolvinglaboratoryscalecrushingandmagneticseparationonyoursuppliedslag This generatesametallurgicalbalancereportprojectingliberationratesandrecoverypotentialwithdifferentmachineconfigurations providinganevidencebased forecast
Q5 Whatistheleadtimefromordertocommissioningforastandardheavydutyslagcrushersplants?
A6 Forstandarddesignsintheheavydutyrange leadtimesaveragebetweenfivesevenmonths This includesmanufacturing factorytesting disassemblyforshipmentandreassemblyonyoursite Modularskiddedunits reduceonsiteassemblytimebyoverhalfcomparedtopiecebuilt plants
