سليگ کولہو پلانٽ پرائيويٽ ليبل ٺاهيندڙ فهرست
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?
ناقابل اعتبار ذريعي: Inconsistent feed size and hard, abrasive materials cause frequent jams in standard crushers, leading to unplanned downtime that halts downstream processing.
اضافي لباس جي قيمت: The highly abrasive nature of slag rapidly degrades standard manganese steel components, resulting in unsustainable expenses for wear parts and labor for changes.
غير موثر آزادي: Inadequate crushing fails to fully liberate metallic content from the slag matrix, causing valuable material to report to waste and reducing overall recovery rates.
اعلي سار سنڀال جي پيچيدگي: Equipment not purposebuilt for this duty cycle requires constant attention, diverting skilled technicians from preventive tasks and increasing mean time to repair (ايم ٽي آر).
پيرن جو نشان & Integration Issues: Can your current material handling flow accommodate another piece of equipment without a major plant redesign?
بنيادي سوال آهي: how do you transform this challenging byproduct into a consistent, profitable stream while controlling operational costs? A dedicated slag crusher plant provides the engineered solution.
2. پيداوار جو جائزو
A private label slag crusher plant is a turnkey system engineered specifically for the primary and secondary reduction of metallurgical slag (ڌماڪي جي باهه, اسٽيل فرنس, ferroalloy). It processes large, irregular slag dumps or tapped slag into a calibrated aggregate or feedstock for further metal recovery.
آپريشنل ڪم فلو:
1. کاڌو & پري اسڪريننگ: رنوفپائل سليگ لوڊر يا ڪنويئر ذريعي کارايو ويندو آهي. An optional initial grizzly screen removes fine undersize material to bypass the crusher, increasing system efficiency.
2. پرائمري ڪرشنگ: هڪ Heavy duty jaw crusher يا اثر بريڪر وڏي سليب کي گھٽائي ٿو (1000mm+ تائين) قابل انتظام سائيز تائين (عام طور تي 200mm هيٺ), applying high inertia force to break along natural cleavage lines.
3. ڌاتو جدا ڪرڻ: The crushed material passes over an overhead magnetic separator (drum or crossbelt) to extract liberated ferrous metal for recycling.
4. ثانوي ڪرشنگ & ماپڻ: A cone crusher or impactor provides final reduction in a closed circuit with a vibrating screen to produce precisely sized fractions (مثال, 05ايم ايم, 520ايم ايم, 2040ايم ايم).
5. ذخيرو ڪرڻ: Sized aggregates are conveyed to designated stockpiles for sale as construction aggregate or further processing.
ايپليڪيشن جو دائرو & حدون:
دائرو: مربوط اسٽيل پلانٽس لاءِ مثالي, اسٽينڊل smelters, سليگ پروسيسنگ گز, and aggregate producers handling ferrous and nonferrous slags.
حدون: Not designed for primary ore processing or extremely soft, غير ڇڪڻ وارو مواد. System output is contingent on feed size consistency and material characteristics (ڇڪڻ واري انڊيڪس).
3. بنيادي خاصيتون
HeavyDuty جبڑے کولہو | ٽيڪنيڪل بنياد: گہرے ڪرشنگ چيمبر & اصلاح ٿيل نپ زاويه | آپريشنل فائدا: Handles large slab feed without bridging; high reduction ratio minimizes secondary stage load | ROI اثر: Reduces primary stage energy consumption by up to 18% versus nonoptimized designs.
Abrasion Resistant لائنر پيڪيج | ٽيڪنيڪل بنياد: Bimetallic composite castings with highchrome inserts in critical wear zones | آپريشنل فائدا: Extends service life of wear parts by 23x compared to standard manganese steel | ROI اثر: Lowers costperton for wear components and reduces changeout frequency by over 60%.
مربوط مقناطيسي علحدگي سرڪٽ | ٽيڪنيڪل بنياد: Permanent magnet drum separator installed at optimal discharge point | آپريشنل فائدا: Recovers liberated tramp metal continuously during operation, protecting downstream conveyors and crushers | ROI اثر: Captures additional revenue stream from scrap metal; prevents costly damage to secondary crushers.
PLC جي بنياد تي ڪنٽرول & نگراني نظام | ٽيڪنيڪل بنياد: Centralized automation with load management and fault diagnostics | آپريشنل فائدا: Allows singleoperator control; provides realtime data on power draw, ذريعي وڃڻ, and fault alerts | ROI اثر: Optimizes production rates; reduces labor requirements and diagnostic time by approximately 30%.
ماڊلر اسڪيڊ مائونٽ ٿيل ڊيزائن | ٽيڪنيڪل بنياد: Heavyduty Ibeam skids تي اڳي گڏ ڪيل ماڊلز | آپريشنل فائدا: Significantly reduces site installation time and civil work costs; simplifies future relocation if needed | ROI اثر: تائين انسٽاليشن جي وقت کي گھٽائي ٿو 40%, وقت جي پيداوار کي تيز ڪرڻ.
HeavyDuty Vibrating Grizzly Feeder | ٽيڪنيڪل بنياد: تبديل ٿيندڙ لينر ۽ اعلي Gforce صلاحيت سان مضبوط ڊيڪ تعمير | آپريشنل فائدا: Ensures consistent feed rate to the primary crusher while scalping out fines; absorbs direct dump impacts from loaders | ROI اثر: Maximizes primary crusher utilization and prevents costly damage from erratic feeding.
Enclosed Conveying with Dust Suppression Points| ٽيڪنيڪل بنياد: Belt conveyors with fulllength skirting and strategically placed spray nozzles| آپريشنل فائدا: Contains fugitive dust at transfer points, maintaining a safer site environment and reducing product loss| ROI اثر: Minimizes water usage compared to fullarea spraying; helps ensure compliance with site environmental regulations.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري حل | پرائيويٽ ليبل سليگ کولہو پلانٽ حل | فائدو (% سڌارو) |
| : | : | : | : |
| ڪپڙا پارٽ لائف (پرائمري) | Standard Manganese Steel Liners | BiMetallic Composite Liners with Chrome Inserts| +150% |
| سسٽم اپ ٽائيم دستيابي| ~8085% (due to jams/wear) |>92% (engineered flow & اجزاء)| +1015% |
| ڌاتو جي بحالي جي ڪارڪردگي| Postcrush magnetic separation only| Inline primary & secondary magnetic separation stages| +25% وصولي جي پيداوار |
| تنصيب & ڪم ڪرڻ جو وقت| Fieldfabricated foundations & اسيمبلي| Preassembled modular skid design|40% وقت |
| مخصوص پاور واپرائڻ(kWh/ٽن)| Varies widely with feed size inconsistency| Optimized circuit with loadsensing drives|15% سراسري |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 50 TPH کان مٿي 300 TPH of processed slag.
فيڊ سائيز وڌ ۾ وڌ: Up to 1000mm x 1200mm slab input.
Final Product Sizing: Adjustable via screen selection; typical ranges from 05mm sand substitute up to 40mm aggregate.
بجلي جي گهرج: ڪل ڳنڍيل لوڊ کان 150 kW کان 600 kW ترتيب تي منحصر ڪري ٿو; 415V/50Hz/3Phase تي معياري فراهمي (ٻيا voltages موجود آهن).
مواد جي وضاحت: پرائمري فريم هيڊي ڊيوٽي اسٽرڪچرل اسٽيل مان ٺهيل آهي (ايس 355 جي آر). Critical wear components use HARDOX or equivalent abrasionresistant steel. Crusher jaws/liners in premium manganese or composite alloys.
جسماني طول و عرض (عام سيٽ اپ): تقريبن 35 ميٽر جي پيرن جو نشان (ايل) x 18m (ڊبليو). Overall height varies but typically under 10m.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 50 ° C تائين محيطي درجه حرارت لاء ٺهيل. Dust suppression system rated for operation where water is available.
6. درخواست جا منظر
انٽيگريٽيڊ اسٽيل پلانٽ سليگ يارڊ ريسائڪلنگ
چيلنج: A major steel producer faced escalating landfill costs for blast furnace slag and needed reliable sizing of material for road base sales while recovering residual iron.
حل: Implementation of a turnkey private label slag crushing plant featuring a heavyduty jaw crusher followed by two stages of magnetic separation before final screening.
نتيجا: Achieved consistent production of 20mm aggregate meeting local spec; increased metal recovery by 22%; reduced offsite disposal costs by 95%; project payback achieved in under 18 months through product sales.
Ferroalloy Smelter ByProduct Processing
چيلنج: A ferrochrome smelter’s existing hammer mill system suffered extreme wear (<200 ڪلاڪ زندگي) on parts due to ultraabrasive slag composition, causing excessive downtime.
حل: Replacement with a configured private label plant using an impact breaker designed for abrasives in closed circuit with specialized alloy liners throughout the flow path.
نتيجا: ورهاڱي جو حصو زندگي کان اڳتي وڌايو 600 hours per set; system availability increased from 90%; maintenance labor hours dedicated to the crushing circuit were reduced by twothirds.
Independent Aggregate Producer Market Expansion
چيلنج: An aggregate company sought entry into the industrial byproducts market but required flexible equipment capable of handling varied feed materials without constant reconfiguration.
حل: Installation of modular private label plant designed around an impactor as the primary unit allows adjustment between different types of slags without major mechanical changes..
نتيجا: Enabled processing contracts across three different local industries producing varying slags within one fiscal year due reduced changeover times between jobs..
تجارتي خيالات
Equipment pricing tiers are structured around throughput capacity:
• Standard Range (50 -150 ٽي پي ايڇ): Base configuration includes primary crushing magnetic separation basic screening PLC controls..
• HighCapacity Range (150 –300+ TPH): Includes larger feeders multiple conveyor lines advanced dust suppression highertier automation..
اختياري خاصيتون شامل آهن:
• Portable wheelmounted chassis..
• Advanced metal detectors nonferrous recovery systems..
• Automated lubrication systems..
• Remote monitoring telemetry packages..
Service packages offered:
• Basic Warranty covering defects parts labor first twelve months operation..
• Extended Support Plans providing scheduled inspections preferential parts pricing technical support hotline access..
Financing options can be discussed including operating leases capital leases leaseto own structures tailored support cash flow requirements facilitate capital approval..
FAQ
What type power supply required operate typical private label slug crushr plnt?
Most configurations require threephase industrial voltage supply typically between kV kVA depending selected capacity Additional transformers may needed consult specifications early planning stages..
How does system handle wet sticky slug conditions common some operations?
Design includes specific features such cascading material flow minimize packing grizzly deck configurations prevent clogging However extremely high moisture content may necessitate predrying blending drier material maintain rated throughput..
What typical lead time delivery commissioning complete plnt?
For standard configurations lead time generally ranges weeks months order confirmation factoring manufacturing shipping Site preparation civil works should commence parallel Modular skid design reduces onsite commissioning period approximately weeks following delivery..
Are spare parts readily available given private label nature equipment?
Yes All critical wearing components use industrystandard interchangeable designs OEM equivalents ensuring multiple sourcing options maintain stock strategic consumables recommended guarantee uptime..
Can existing conveyors other infrastructure integrated new crushr plnt?
Integration possible requires detailed review existing layout capacities Our engineering team can assess provide interface drawings recommendations necessary modifications ensure seamless material handoff..
What metrics used quantify return investment ROI such project?
Key metrics include increased revenue recovered metal sale sized aggregate decreased disposal landfill tipping fees reduced maintenance downtime labor costs combined calculate overall payback period Field data shows typical payback achieved within months based current commodity operating cost structures..
