Slag Crusher Plant Suppliers Design Service
1. PAINPOINT driven اوپننگ
ڇا توهان اسٽيل پلانٽ يا سليگ پروسيسنگ يارڊ جو انتظام ڪري رهيا آهيو ۽ توهان جي مادي بحالي واري زنجير ۾ مسلسل رڪاوٽن کي منهن ڏئي رهيا آهيو? The challenges with traditional slag handling are quantifiable and costly. Inconsistent feed size jams crushers, causing unplanned downtime that costs thousands per hour in lost production and labor. Abrasive slag components rapidly wear out standard crushing chambers, بار بار جي اڳواڻي, expensive liner replacements and parts inventory burdens. ان کان سواء, inefficient separation results in valuable metallic content being lost to waste stockpiles, directly impacting your revenue recovery. Dust generation creates environmental and health compliance issues, while inflexible equipment cannot adapt to varying slag types or production demands.
پلانٽ مينيجرز لاءِ مرڪزي سوال واضح آهي: توهان ڪيئن قابل اعتماد حاصل ڪري سگهو ٿا, highvolume slag processing with lower operating costs and maximized metal yield? The answer requires a purposeengineered system, not just a standard crusher.
2. پيداوار جو جائزو
اي Slag Crusher Plant is a stationary or semimobile integrated processing system designed specifically for the size reduction and liberation of metallic content from steel slag, ڌماڪي واري فرنس سليگ, and similar industrial byproducts. اهو خام بدلائي ٿو, lump slag into a graded, marketable aggregate while recovering ferrous metal for recycling.
آپريشنل ڪم فلو:
1. پرائمري ڪرشنگ & اسڪريننگ: وڏيون ڍڳيون ڍڳيون (1000mm تائين) are reduced by a primary jaw crusher. A preliminary screen removes fine material.
2. مقناطيسي علحدگي (پرائمري): A suspended magnet over the conveyor extracts the majority of liberated ferrous metal postprimary crushing.
3. ثانوي ڪرشنگ: A cone crusher or impactor further reduces the material to achieve optimal liberation of embedded metal.
4. فائنل اسڪريننگ & جدائي: Material is classified into precise aggregate sizes (مثال, 05ايم ايم, 510ايم ايم, 1020ايم ايم). A second drum magnet ensures final metal recovery.
5. ذخيرو ڪرڻ: Clean aggregate is conveyed to stockpiles; recovered metal is collected for sale or reuse.
ايپليڪيشن جو دائرو: Integrated steel plants, اسٽينڊل سليگ پروسيسنگ گز, mining operations handling abrasive materials.
حدون: Not designed for highly corrosive chemical slags or as a primary ore processing plant without significant configuration changes.
3. بنيادي خاصيتون
HeavyDuty وائبريٽنگ فيڊر | ٽيڪنيڪل بنياد: Grizzly section with adjustable spacing | آپريشنل فائدا: Removes subgrade fines and prevents primary crusher overload | ROI اثر: تائين کولہو جي لباس کي گھٽائي ٿو 15% and improves overall throughput stability.
Jaw Crusher with Manganese Steel Jaws | ٽيڪنيڪل بنياد: High compression crushing with optimized nip angle | آپريشنل فائدا: Effectively processes large, irregular slag lumps with high compressive strength | ROI اثر: فيلڊ ڊيٽا ڏيکاري ٿو a 2030% longer service life compared to standard jaws in abrasive applications.
Electromagnetic Suspended Magnet | ٽيڪنيڪل بنياد: Deep magnetic field penetration across full conveyor width | آپريشنل فائدا: Recovers large tramp metal اڳ ثانوي ڪٽڻ جا مرحلا | ROI اثر: Protects downstream equipment from damage and captures highvalue scrap early in the process.
Liner Protection System (Cone/Impactor) | ٽيڪنيڪل بنياد: Hydraulic adjustment and overload relief cylinders | آپريشنل فائدا: Allows quick clearing of uncrushables and protects major components from catastrophic failure | ROI اثر: Minimizes risk of costly repairs and reduces mean time to repair (ايم ٽي آر) by hours.
بند ٿيل پهچائڻ & Dust Suppression Points | ٽيڪنيڪل بنياد: Sealed transfer points with strategically placed spray nozzles | آپريشنل فائدا: Controls airborne particulate at critical generation points | ROI اثر: Mitigates environmental noncompliance risks and reduces site cleanup costs.
مرڪزي PLC ڪنٽرول سسٽم | ٽيڪنيڪل بنياد: Automated sequencing with fault annunciation | آپريشنل فائدا: Enables smooth plant startup/shutdown and provides operators with clear diagnostic information | ROI اثر: Lowers operator error potential and simplifies troubleshooting.
ماڊلر اسڪيڊ ڊيزائن (اختياري) | ٽيڪنيڪل بنياد: Preassembled structural frames for key modules | آپريشنل فائدا: Reduces civil works cost and accelerates onsite installation time by an estimated 30% | ROI اثر: Faster commissioning leads to earlier production revenue.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | Slag Crusher Plant Solution | فائدو (% سڌارو) |
|||||
| ڌاتو جي بحالي جي شرح | ~9092% | تائين 9698% | +68% حاصلات |
| لائنر زندگي (پرائمري اسٽيج) | 80,000 100,000 MT processed | 120,000 150,000 MT processed | +4050% پائيداري |
| سسٽم اپ ٽائيم دستيابي 95% 97%+ +2% دستيابي |
| Specific Power Consumption Baseline 1015% reduction through optimized drive systems 1015% توانائي جي بچت |
| Dust Emission at Transfer Points Often requires addon bag filters Meets standards via integrated suppression Lower Capex on Dedicated Filtration |
Based on scheduled maintenance adherence.
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: کان ترتيب ڏئي سگهجي ٿو 50 TPH کان مٿي 300 ٽي پي ايڇ.
کاڌ خوراڪ جي ماپ: Accepts lump slag up to 1000mm edge length.
بجلي جي گهرج: Total connected load typically between 250kW 800kW depending on configuration; 415V/3Phase/50Hz لاءِ فراهم ڪئي وئي يا جيئن بيان ڪيل.
مواد جي وضاحت: Primary wear parts (لينر, جبل) manufactured from Grade III Manganese Steel or equivalent AR plate; structural frames from heavyduty ISMC/ISMB sections.
جسماني طول و عرض: گنجائش جي لحاظ کان مختلف آهي; هڪ معيار 150 TPH plant footprint is approximately 35m (ايل) x 22m (ڊبليو) x 15m (ايڇ).
ماحولياتي آپريٽنگ رينج: 10 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; dust and weather protection standard for outdoor installation.
6. درخواست جا منظر
Integrated Steel Plant Slag Yard Retrofit
چيلنج:
A major steel producer faced frequent breakdowns in their aging twostage crushing setup. ڌاتو جي بحالي غير موثر هئي (~ 88%), leading to significant value loss in aggregate stockpiles. بند ٿيڻ جو وقت وڌي ويو 15 ڪلاڪ مهيني.
حل:
Implementation of a turnkey Slag Crusher Plant featuring a robust grizzly feeder, deepfield magnetic separators at two stages, and an automated cone crusher for secondary reduction.
نتيجا:
ڌاتو جي وصولي تي وڌي وئي 96%. سسٽم جي دستيابي پهچي وئي >97%, reducing monthly downtime to under <5 ڪلاڪ. The recovered additional metal paid for the plant's operational costs within eight months.
آزاد سليگ پروسيسنگ ٺيڪيدار
چيلنج:
A contractor needed mobile flexibility but required higher volume than portable crushers offered. Their challenge was inconsistent feed material from multiple small steel mills.
حل:
A semimobile Slag Crusher Plant built on modular skids with quickdisconnect electrical/utility connections was deployed.
نتيجا:
The plant could be relocated between sites within one week using conventional heavy transport. This flexibility allowed the contractor to service multiple clients without capital duplication while maintaining highvolume processing efficiency above >120 TPH consistently across varied feed materials.
7. تجارتي خيالات
قيمت جا درجا: Capital cost varies significantly based on capacity and automation level.
داخلي سِطح: Manual/semiautomated plants up to ~75 TPH focus on core functionality.
معياري: Fully automated plants (~75200 TPH), including PLC control dust suppression represent the most common investment range
اعلي ظرفيت: Customengineered systems (>200 ٽي پي ايڇ) often include advanced monitoring systems like liner wear sensors
اختياري خاصيتون & واڌارو: Vibrating screen decks for additional product fractions; metal baler/shear for scrap processing; خودڪار lubrication نظام; remote monitoring via SCADA
سروس پيڪيجز: Annual Maintenance Contracts (AMC), guaranteed spare parts supply agreements are available
فنانسنگ جا اختيار: Equipment leasing structures are commonly offered through partner financial institutions
8.FAQ
1.ق:What if our incoming slag composition varies significantly?
اي:The design incorporates adjustable crusher settings variable speed feeders allowing operators finetune throughput product size based realtime feed characteristics ensuring consistent output quality
2.ق:تنصيب جون عام ضرورتون ڪهڙيون آهن?
اي:A level prepared base adequate electrical supply water connection dust suppression essential Detailed foundation layout drawings comprehensive utility specifications provided prior delivery facilitate smooth site preparation
3.ق:اسان کي ڪهڙي جاري سار سنڀال جي اميد رکڻ گهرجي?
A.Primary maintenance involves regular inspection replacement wear parts like crusher liners conveyor belts spray nozzles Scheduled lubrication critical bearings drives Welldesigned plant provides easy safe access all service points reduce labor time
4.Q.How does this integrate with our existing material handling equipment?
A.Plants are engineered accept feed from your current loaders conveyors Output conveyors can be positioned suit your existing stockpiling loading arrangements Control systems can often interface with broader site networks
5.Q.What warranty support do you provide?
A.A standard warranty covers manufacturing defects major components typically months extended warranties available purchase Comprehensive documentation includes operation manuals parts lists recommended maintenance schedules ensure your team fully supported
