Slag Crusher Plant Producers 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?
ناقابل اعتبار ذريعي & بند وقت: Inconsistent feed size and tramp metal cause frequent jams in standard crushers, halting your entire material recovery line and delaying downstream processing.
زيادتي پائڻ & سار سنڀال جا خرچ: The highly abrasive nature of slag rapidly degrades standard manganese steel components, leading to unscheduled shutdowns and high spare part expenditures.
Inefficient Liberation of Valuables: Inadequate crushing fails to fully liberate metallic fractions (ferrous and nonferrous) from the slag matrix, leaving recoverable value in your waste stream and reducing overall plant revenue.
مٽي & Environmental Control Issues: Dry crushing processes generate significant fugitive dust, creating environmental compliance risks and unsafe working conditions for personnel.
If these issues are impacting your profitability, the central question is: توهان ڪيئن هڪجهڙائي حاصل ڪري سگهو ٿا, highvolume slag reduction with lower operational costs and maximized metal recovery? جواب هڪ مقصد انجنيئر ۾ آهي Slag Crusher Plant.
2. پيداوار جو جائزو
اي Slag Crusher Plant is a stationary or semimobile processing system specifically engineered for the primary, ثانوي, ۽ ڪڏهن ڪڏهن ميٽالرجيڪل سليگ جي ٽيٽيري ڪرشنگ (ڌماڪي جي باهه, اسٽيل فرنس, ٽامي, وغيره). Its design prioritizes durability against abrasion and impact while ensuring efficient liberation of entrapped metals.
آپريشنل ڪم فلو:
1. کاڌو & پري اسڪريننگ: Runofpile slag is fed via loader or conveyor into a vibrating grizzly feeder, جيڪو سڪل جزن کي ختم ڪري ٿو (30ايم ايم) پرائمري کولہو کي بائي پاس ڪرڻ لاءِ, increasing system efficiency.
2. پرائمري ڪرشنگ: Oversize material is reduced by a heavyduty jaw crusher or impactor designed for high compressive strength feed.
3. ڌاتو جدا ڪرڻ & ثانوي ڪرشنگ: The crushed product typically passes over an overhead magnetic separator to remove liberated ferrous scrap. The remaining material is further reduced by a cone crusher or secondary impactor to achieve the target grain size (مثال, 20ايم ايم).
4. ماپڻ & ذخيرو ڪرڻ: A final vibrating screen classifies the product, with oversize material recirculated. Onspec material is conveyed to stockpile for sale as aggregate or for further processing.
ايپليڪيشن جو دائرو: مربوط اسٽيل پلانٽس لاءِ مثالي, بدبودار, سليگ پروسيسنگ گز, and aggregate producers handling ferrous and nonferrous slags.
حدون: Not designed for primary mining of virgin rock or for processing materials with extreme moisture or clay content without preconditioning.
3. بنيادي خاصيتون
HeavyDuty Vibrating Grizzly Feeder | ٽيڪنيڪل بنياد: Highstrength eccentric shaft drive | آپريشنل فائدا: Removes fines upfront, regulates feed to the primary crusher preventing chokefeeding | ROI اثر: Reduces primary crusher load by up to 30%, lowering wear and energy consumption per ton processed.
AbrasionResistant Liner Packages | ٽيڪنيڪل بنياد: Airhardening manganese steel or composite ceramic/metal alloys | آپريشنل فائدا: لائنر جي زندگي وڌايو ويو 4060% compared to standard manganese in highabrasion zones | ROI اثر: Decreases downtime for liner changes and reduces annual spare parts inventory cost.
مربوط مقناطيسي علحدگي سرڪٽ | ٽيڪنيڪل بنياد: اوور بينڊ خود صاف ڪرڻ وارا مقناطيس بهترين خارج ٿيڻ واري پوائنٽن تي رکيل آهن | آپريشنل فائدا: Continuously extracts liberated ferrous metal during crushing stages | ROI اثر: Creates a direct revenue stream from scrap recovery and protects downstream conveyors and crushers from metal damage.
مرڪزي گريسنگ & هائيڊولڪ سسٽم | ٽيڪنيڪل بنياد: Automated lubrication points for bearings and hydraulic adjustment/tramp release systems | آپريشنل فائدا: Ensures critical components are lubricated under all operating conditions; allows quick clearing of uncrushables | ROI اثر: تباهي واري بيئرنگ ناڪامي کي روڪي ٿو (a major cause of downtime) and minimizes manual maintenance intervention time.
ڊسٽ سپپريشن سسٽم انٽيگريشن | ٽيڪنيڪل بنياد: سولينائڊ ڪنٽرول سان پاڻي جي فراهمي سان ڳنڍيل منتقلي پوائنٽن تي Nozzle arrays | آپريشنل فائدا: Effectively controls dust emissions at source during crushing operations | ROI اثر: ماحولياتي غير تعميل جي خطرن کي گھٽائي ٿو ۽ گھر جي سنڀال جي مزدورن جي خرچن کي گھٽائي ٿو.
Robust Structural Fabrication | ٽيڪنيڪل بنياد: Stiffened frame design with heavyduty crawler or fixed plant support legs | آپريشنل فائدا: Maintains alignment under continuous highvibration loads over years of operation | ROI اثر: Eliminates costly structural repairs and prevents premature failure of mounted components due to frame flexing.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معياري حل | اسان جي Slag Crusher پلانٽ حل | فائدو (% سڌارو) |
| : | : | : | : |
| دستيابي / اپٽائم | 8085%, frequent jamming from tramp metal >8592%, hydraulic tramp release clears uncrushables in 8% واڌارو |
| پرائمري اسٽيج ۾ لائنر زندگي (ايم اين اسٽيل) ~40,000 MT throughput ~60,000 MT throughput >50% سڌارو |
| Specific Power Consumption ~0.8 1.0 kWh/ton ~0.65 0.75 kWh/ٽن >20% گهٽتائي |
| Metal Recovery Efficiency Manual picking postcrushing Inprocess magnetic separation at 2 stages Scrap recovery yield increased by 1525% |
| Dust Emission at Transfer Points Dry crushing with local extraction Wet suppression system at source PM10 emissions reduced by >90% |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 50 TPH کان مٿي 300 TPH پروسيس ٿيل سليگ.
بجلي جي گهرج: ڪل نصب ٿيل طاقت عام طور تي حد تائين 150 ڪلواٽ (لاءِ 50 TPH پلانٽ) جي طرف 450 ڪلواٽ (لاءِ 300 TPH پلانٽ), ترتيب تي منحصر آهي.
مواد جي وضاحت: Primary crusher jaws/liners manufactured from premiumgrade Manganese Steel (1822%). Critical wear plates utilize AR400 steel. Structural frames fabricated from heavyduty ISMC/ISMB sections.
جسماني طول و عرض (عام 150 TPH پلانٽ): ڊگھائي (~25m) x ويڪر (~ 8 م) x اوچائي (~7 م). Available in fixed skidmounted or semimobile trailer versions.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 50 ° C تائين محيطي درجه حرارت لاء ٺهيل. مٽي کي دٻائڻ واري نظام کي صاف پاڻي جي فراهمي جي ضرورت آهي 3040 پي ايس آءِ; consumption approx. 50 liters per ton crushed.
6. درخواست جا منظر
انٽيگريٽيڊ اسٽيل پلانٽ سليگ يارڊ چيلنج:
A major steel producer faced inconsistent feed from aged stockpiles causing daily chokeups in their existing crusher, limiting aggregate production to just one shift per day due to maintenance needs.
حل:
هڪ ٽرنڪي جو نفاذ Slag Crusher Plant featuring an extradeep crushing chamber jaw crusher with hydraulic toggle adjustment for quick CSS changes, paired with a powerful overhead magnet on the primary discharge belt.
نتيجا:
Plant availability increased to three full shifts. Aggregate production rose by 210%. Recovered ferrous scrap generated sufficient revenue to cover the plant’s operating labor costs annually.
Copper Smelter Tailings Reprocessing Challenge:
A smelter sought to recover residual copper from old dump slag but found that conventional hammer mills created excessive fines (3ايم ايم), rendering gravity separation ineffective.
حل:
A twostage Slag Crusher Plant using a jaw crusher followed by a cone crusher in closed circuit with a screen was deployed for controlled size reduction targeting 12mm+3mm.
نتيجا:
The optimized grain size distribution improved recovery rates in the downstream jig plant by over 18%. The robust design handled the highly abrasive silicarich slag with liner life meeting projected targets.
7. تجارتي خيالات
قيمت جا درجا: Solutions are projectspecific but generally fall into three categories:
Standard SkidMounted Plant (50100 ٽي پي ايڇ): A costeffective entry point for lower volume processors.
Modular MediumCapacity Plant (100200 ٽي پي ايڇ): The most common configuration offering optimal balance of output and investment.
HighCapacity Fixed Stationary Plant (200300+ ٽي پي ايڇ): Designed for largescale producers requiring maximum uptime and automation.
اختياري خاصيتون: Vibrating feeder vs apron feeder; secondary cone vs impact crusher; automated metal detection system; advanced PLC control panels with remote monitoring capability; آواز جي بندش.
سروس پيڪيجز: توسيع وارنٽي منصوبن; سالياني معائنو معاهدو; guaranteed spare parts delivery schedules (مثال, 48hour critical parts availability).
فنانسنگ جا اختيار: پارٽنر مالياتي ادارن ذريعي سامان ليز تي ڏيڻ; milestonebased project payment plans for turnkey installations.
8. FAQ
1. Is your Slag Crusher Plant compatible with our existing conveyors and material handling infrastructure?
Our engineering team can design transfer heights and discharge points to match your current layout during the project specification phase.
2. متوقع آپريشنل شور جي سطح ڇا آهي?
With standard equipment enclosures, فيلڊ جي ماپ عام طور تي هيٺيون سطحون ڏيکاريو 85 ڊي بي(اي) at a distance of one meter from the machinery when processing dry slag.
3. انسٽاليشن ڪيترو وقت وٺندو?
For a skidmounted plant delivered preassembled on our frames, onsite commissioning can be completed within two weeks after foundation readiness upon arrival at your site
4.ڇا توهان ڪارڪردگي جي ضمانت فراهم ڪري سگهو ٿا?
Yes we offer guaranteed minimum throughput capacity based on defined feed material characteristics as well as maximum power consumption per ton
5.عام ادائگي جون شرطون ڇا آهن?
For custom plants terms are generally structured as follows
30% advance payment
60% against dispatch
10% after successful commissioning
6.Do you offer training for our operators
Comprehensive training covering operation routine maintenance safety procedures troubleshooting is provided onsite during commissioning
7.How do you handle warranty claims
We maintain regional service hubs Warranty claims initiate through our service manager who coordinates diagnostics part dispatch if needed technician deployment if required
