Ce Marked Slag Crusher Plant Quote
1. HAPJE NGA PIKA E DIKIMIT
Managing slag byproduct is a persistent operational bottleneck with tangible costs. A po përballeni me këto sfida?
Koha e lartë e ndërprerjes për Thërrmuesit kryesorë: Uncrushed slag with oversized metal inclusions causes frequent jams in primary crushers, leading to hours of unplanned maintenance and lost processing time.
Trajtimi joefikas i materialeve & Renditja: Manual or rudimentary separation of valuable scrap metal from aggregate is laborintensive, inconsistent, and represents a loss of recoverable revenue.
Downstream Equipment Damage: Unidentified tramp metal and uncrushable debris bypass initial processing, causing accelerated wear or catastrophic failure in conveyors, ekranet, dhe thërrmuesit dytësorë.
Inconsistent Feed Size for Processing: Variable slag feed results in an inconsistent product size, reducing the efficiency and quality control of your final aggregate or feedstock.
The core question for plant managers is: how can you transform a costly waste stream into a controlled, profitable material flow while protecting your core crushing circuit?
2. PËRMBLEDHJE E PRODUKTIT
A CEMarked Slag Crusher Plant is a purposebuilt, stationary or semimobile processing system designed for the primary reduction and liberation of slag from steel mills, shkritoret, and metal production facilities. Its design prioritizes the handling of abrasive, heterogeneous material containing metallic inclusions.
Rrjedha e punës operative:
1. Feed & Para-Screening: Skorjet e furrës së rrjedhjes futen nëpërmjet ngarkuesit në një plesht të fortë, shpesh me një seksion grizzly për të anashkaluar materialin nën madhësi.
2. Primary Liberation Crushing: Thërrmuesi bërthamë (zakonisht një tip nofull ose ndikimi) aggressively reduces the slag mass, breaking it apart to liberate embedded metallic components.
3. Ndarja e metaleve & Nxjerrja: Materiali i grimcuar kalon mbi një ndarës magnetik sipër (suspended magnet or magnetic pulley), which automatically extracts ferrous scrap for recovery.
4. Përmasat & Grumbullimi i rezervave: The separated aggregate fraction is conveyed to a primary stockpile or directly to a secondary screening circuit for further grading.
Fusha e Aplikimit: Ideale për fabrikat e integruara të çelikut, kantiere të pavarura të përpunimit të skorjeve, and aggregate producers specializing in secondary materials. Best suited for ferrous slag (BOF, EAF). Performance on nonferrous slags requires specific configuration.
Kufizimet: Not a substitute for fine grinding or tertiary crushing circuits. Feed size is limited by the primary crusher opening. Optimal operation requires material with a manageable moisture content to prevent clogging.
3. TIPARET THEMELORE
HeavyDuty Grizzly Feeder | Baza Teknike: Prescreening & ushqim i rregulluar | Përfitimi Operacional: Removes fines prior to crushing and ensures a consistent, controlled feed rate to the crusher chamber | Ndikimi i ROI: Rrit xhiron e thërrmuesit deri në 15% and reduces wear on crusher liners
Reinforced Jaw Crusher Chamber | Baza Teknike: High manganese steel liners & kënd i optimizuar i kapjes | Përfitimi Operacional: Withstands extreme abrasion and shock loads from uncrushable metals; hydraulic toggle adjustment allows quick setting changes | Ndikimi i ROI: Reduces liner replacement frequency by ~30% versus standard configurations
Integrated Overband Magnetic Separator | Baza Teknike: Permanent magnet or electromagnetic circuit mounted over discharge conveyor | Përfitimi Operacional: Automatically extracts liberated ferrous scrap continuously during operation without stopping the process flow | Ndikimi i ROI: Kap 95%+ of recoverable metal, creating a direct revenue stream from waste
Grasimi i centralizuar & Sistemi Hidraulik | Baza Teknike: Singlepoint lubrication lines for key bearings and hydraulic controls for adjustment/clearing | Përfitimi Operacional: Mundëson të sigurt, routine maintenance in under 30 minuta; allows operators to clear blockages remotely | Ndikimi i ROI: Cuts planned maintenance time by half and minimizes personnel exposure to equipment internals
CE Certified Safety Guards & Qasja në platforma | Baza Teknike: Pajtueshmëri e plotë me Direktivën e BE-së për Makineri 2006/42/EC | Përfitimi Operacional: Ofron të sigurt, compliant access for inspection and maintenance; interlocks prevent operation during servicing | Ndikimi i ROI: Mitigates risk of regulatory noncompliance fines and reduces workplace incident potential
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi i Industrisë (Basic Crushing) | CEMarked Slag Crusher Plant Solution | Avantazhi (% Përmirësimi) |
| : | : | : | : |
| Shkalla e rikuperimit të metaleve | Zgjedhja manuale e pasthërmimit (~7080%) | Continuous automated extraction during process (>95%)| +20% Efikasiteti i Rimëkëmbjes |
| Crusher Downtime due to Tramp Metal| 812 hours per month for clearing/repair| Më pak se 2 hours per month with hydraulic clearing| ~80% Reduction in Unplanned Stops |
| Liner Life in Abrasive Service| Përafërsisht. 60,000 ton për grup| Përafërsisht. 85,000 ton për grup (reinforced)| ~40% Longer Service Life |
| Process Consistency (Kontrolli i ushqimit)| Manual loader feeding (e ndryshueshme)| Grizzly feeder + regulated flow (konsistente)| Throughput stability improved by ~25% |
5. SPECIFIKIMET TEKNIKE
Gama e Kapacitetit: I konfigurueshëm nga 50 te 400 ton në orë.
Opsionet primare të thërrmuesit: Mallkimi i nofullës (models from 750x500mm to 1200x1000mm) or Impact Crusher with hydraulic adjustment.
Kërkesat për fuqi: Fuqia totale e instaluar zakonisht ndërmjet 90 kW 250 kW, në varësi të konfigurimit (400V/50Hz standard).
Specifikimet kryesore të materialit:
Liners Crusher: AR400 / Hardox steel or premium manganese steel.
Rripa transportues: Minimum EP400/3 with abrasionresistant covers.
Korniza strukturore: Heavyduty welded sections from S355JR steel.
Dimensionet fizike (Konfigurimi tipik): Approximate footprint of 20m L x 8m W x 7m H. Designed for flat concrete foundation.
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 10°C deri në +45°C. Dust suppression spray bars are fitted as standard at transfer points.
6. Skenarët e APLIKIMIT
Integrated Steel Mill – BOF Slag Processing | Sfida: A European mill faced daily downtime in its aggregate plant due to oversized slag chunks containing "skulls" jamming their existing crusher. Manual metal recovery was inefficient.| Zgjidhje: Installation of a CEMarked Slag Crusher Plant with a heavyduty jaw crusher and powerful overband magnet at the slag tipping point.| Rezultatet: Unplanned crusher stoppages were eliminated. The plant now recovers an additional €45,000 annually in ferrous scrap sales and produces consistent 150mm aggregate for internal roadbase use.
Kontraktor i pavarur i përpunimit të skorjeve | Sfida: A contractor needed to process varying stockpiles of EAF slag at multiple sites but required compliance with EU site safety regulations.| Zgjidhje: A semimobile skidmounted CEMarked Slag Crusher Plant was selected.| Rezultatet:The unit can be relocated between sites within days while maintaining full CE compliance at each location. Contractual penalties related to noncompliant equipment were avoided.
7. KONSIDERATA TREGTARE
Our CEMarked Slag Crusher Plants are offered in three primary tiers:
Uzina standarde e detyrës: For lowervolume operations (<100tph). Includes core jaw crusher,magnet,dhe transportues bazë të shkarkimit.
Fabrika me detyrë të rëndë: For highvolume steel mills (>200tph). Features reinforced impactor option,ushqyes grizzly vibrues,and multiple magnetic separation stages.
SemiMobile Skid Plant: For multisite contractors.All core components mounted on heavyduty skidsfor transportability.
Karakteristikat opsionale përfshijnë:
- Secondary screening unit
- Advanced dust suppression system
- Metal fragmentizer attachment
- Paketa telematike e monitorimit në distancë
We offer comprehensive service packages including scheduled maintenance plans,lifetime technical support,and guaranteed parts availability within48 hoursfor critical components.Financing options include capital purchase,tailored leasing agreements,dhe strukturat me qira.
8.FAQ
Q1.Is this plant compatible with our existing conveyor system?
A1.Field data shows integration is straightforward.The plant's discharge heightand conveyor speed are engineeredto match standard downstream systems.We require your existing specificationsfor confirmation.
Q2.What is the expected operational cost per tonne processed?
A2.Based on configured powerand typical wear part consumption,costs range between €0 .80and €1 .50per tonne.This includes power,lubrifikantët,and liner wear but excludes labor.Scrap metal revenue typically offsetsa significant portionof this cost.
Q3.How does CE marking affect installation timelines?
A3.CE marking signifies all safetydocumentationis preassembled.This can reduce commissioning timeby approximately15%as no retrofittingof guardsor safety systemsis required.Compliance documentationis provided upfrontfor site authority review.
Q4.Can it handle wetor sticky slag?
A4.The standard configuration performs optimallywith material moisture content below10%.For higher moisture,a hydraulic jaw crushera combinedwith specific hopper designsare availableas options toprevent bridgingand clogging
Q5.What warrantyis providedon major components?
A5.We providea24monthwarrantyon structural componentsanda12monthwarrantyon mechanicaland electricalpartsagainst manufacturing defects.Wear parts(veshje dërrmuese)are coveredunder aseparateperformancebased warrantyterm
Q6.Are operator trainingand manuals included?
A6.Comprehensive documentationincludingCE Declarationsof Conformityinstallation manualsand parts listsare standard.We provideonsite operational trainingfor your crewover two daysat commissioning
Q7.Do you offer performance guarantees?
A7.We contractually guaranteecapacity throughputwithin5%of specified ratingmetal recovery ratesabove95%for liberated ferrous materialand thatthe plantwill meetall declaredCE safety standards
