Fabrika e bimëve për polic skorjesh në përputhje Rohs
1. HAPJE NGA PIKA E DIKIMIT
Menaxhimi i skorjes është një pengesë e vazhdueshme me kosto të prekshme. A po përballeni me këto sfida operacionale??
Kohë joproduktive të paplanifikuara: Frequent breakdowns of underengineered crushers halt downstream processing, kushton mijëra në orë në prodhim dhe punë të humbur.
Veshja e tepërt & Shpenzimet e Mirëmbajtjes: Lëndë gërryese, unpredictable nature of slag rapidly degrades standard components, leading to unsustainable parts replacement cycles and maintenance labor expenses.
Produkt jo konsistent & Cilësia e produktit: Poor crushing yields uneven particle size distribution, compromising the value of your final aggregate product and causing issues in subsequent material handling or sales.
Rregullatore & Environmental Risk: Noncompliant equipment can lead to site violations, while dust and debris from inefficient processing create unsafe working conditions and potential liability.
Pyetja thelbësore është: how do you transform this problematic byproduct into a consistent, profitable product line without sacrificing reliability or compliance? The answer requires a purposebuilt system designed for the task.
2. PËRMBLEDHJE E PRODUKTIT
A RoHS Compliant Slag Crusher Plant is a stationary or semimobile processing system engineered specifically to reduce slag from metallurgical processes (furra shpërthyese, furre çeliku) në madhësi të caktuara të agregatit. It is constructed with materials and components that adhere to the Restriction of Hazardous Substances (RoHS) direktivë, ensuring no controlled substances are present in the machinery itself—a critical factor for operations with strict environmental procurement policies or those selling aggregate into regulated markets.
Rrjedha e punës operative:
1. Thërrmimi primar: Dumpfed slag is reduced by a robust primary jaw crusher capable of handling large, irregular feed.
2. Para-Screening & Ndarja: A vibrating grizzly or scalper removes fine material and debris prior to secondary crushing, improving overall efficiency.
3. Thërrmimi sekondar: A cone crusher or impact crusher further reduces the material to the target product size.
4. Shfaqja përfundimtare & Grumbullimi i rezervave: Crushed material is classified via vibrating screens into commercial fractions (p.sh., 05mm, 520mm) dhe përcillen në rezervat e caktuara.
Fusha e Aplikimit: Ideale për fabrikat e integruara të çelikut, kantiere të pavarura të përpunimit të skorjeve, dhe prodhuesit e agregatit të specializuar në nënproduktet industriale. Best suited for ferrous slags with moderate to high abrasiveness.
Kufizimet: Not designed for primary rock mining of virgin stone or for processing nonabrasive materials where a simpler system would suffice. Madhësia maksimale e ushqimit dhe fortësia përcaktohen nga modeli kryesor i thërrmuesit të zgjedhur.
3. TIPARET THEMELORE
Thërrmuesi kryesor HeavyDuty | Baza Teknike: Nofullat e përforcuara prej çeliku mangan & kushinetat me përmasa të mëdha | Përfitimi Operacional: Sustained throughput with infrequent wear part changes, handles large slablike slag pieces | Ndikimi i ROI: Reduces primary station downtime by up to 30% annually versus standard crushers
RoHSCompliant Construction | Baza Teknike: Documentationbacked supply chain for motors, instalime elektrike, hidraulikë, dhe veshjet | Përfitimi Operacional: Eliminates risk of noncompliant materials contaminating your process chain or final product | Ndikimi i ROI: Protects market access for your aggregates and avoids costly procurement audits or remediation
Sistemi i integruar i frenimit të pluhurit | Baza Teknike: Grykë spërkatës të vendosura në mënyrë strategjike me kontroll solenoid të lidhur me funksionimin e policit | Përfitimi Operacional: Maintains visible dust levels well below OSHA thresholds, creating a safer environment | Ndikimi i ROI: Minimizes housekeeping labor and reduces wear on plant components caused by abrasive dust
Grasimi i centralizuar & Monitorimi | Baza Teknike: Automated lubrication points for key bearings with lowlevel alerts | Përfitimi Operacional: Extends bearing life in highcontamination environments; provides operators with clear system health status | Ndikimi i ROI: Parandalon dështimet katastrofike të kushinetës, reducing unscheduled maintenance events
Modular Discharge Conveying | Baza Teknike: Customizable radial conveyors or fixed stackers for segregated product stockpiling | Përfitimi Operacional: Enables precise sorting of multiple product grades simultaneously without rehandling | Ndikimi i ROI: Increases saleable product yield by minimizing crosscontamination of size fractions
Veshje rezistente ndaj gërryerjes | Baza Teknike: AR400 steel plate liners in hoppers, bie, and skirts at critical wear points | Përfitimi Operacional: Dramatically extends service life in highimpact zones between crusher stages | Ndikimi i ROI: Lowers annual liner replacement costs and associated installation labor
Paneli i kontrollit i bazuar në PLC | Baza Teknike: Simple automated sequencing with fault diagnostics displayed locally | Përfitimi Operacional: Allows for quick startup/shutdown sequences and faster troubleshooting by your electrical team | Ndikimi i ROI: Reduces operator error and shortens mean time to repair (MTTR)
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi i Industrisë | Zgjidhje impianti për thërrmues skorjesh në përputhje me RoHS | Avantazhi (% përmirësim) |
|||||
| Veshin Part Life (Nofulla primare) | 6090 ditë në detyrë të rëndë skorje | 120150 days with optimized metallurgy | Deri në 67% më gjatë |
| Disponueshmëria në kohën e funksionimit të sistemit | ~8085% due to reactive maintenance | Synimi i 9295% with predictive features | ~12% increase |
| Kontrolli i emetimit të pluhurit | Passive measures (funde, occasional water) | Active suppression system integrated at source >60% reduction in airborne particulates |
| Energy Consumption per Ton Varies widely; often inefficient motor/crusher pairing Crusher & conveyor motors sized for optimal load Documented 815% reduction based on load analysis |
| Compliance Documentation Often limited; generic component certificates Full material declarations for major assemblies 100% traceability for regulated substances |
5. SPECIFIKIMET TEKNIKE
Kapaciteti përpunues: I konfigurueshëm nga 50 TPH deri në fund 300 TPH.
Madhësia e furnizimit: Accepts slag up to 800mm edge length (varur nga modeli).
Kërkesat për fuqi: Primary plant motor load typically ranges from 150 kW në 400 kW; total connected load includes conveyors and auxiliaries. Designed for 400V/50Hz or other industrial standards.
Specifikimet e materialit: Primary frame construction from heavyduty S355 steel; critical wear areas lined with AR400/AR500 abrasionresistant steel; all electrical components from RoHScompliant manufacturers.
Dimensionet fizike (Konfigurimi tipik): Footprint approximately 25m L x 15m W x 12m H (ndryshon ndjeshëm me konfigurimin).
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 20°C deri në +45°C; dust suppression system rated effective up to wind speeds of level 5.
6. Skenarët e APLIKIMIT
Integrated Steel Mill – Slag Yard Modernization
Challenge A major steel producer faced escalating disposal costs for granulated blast furnace slag and frequent breakdowns of aging mobile crushers causing production delays at their melt shop.
Solution Implementation of a turnkey RoHS Compliant Slag Crusher Plant with integrated scalping screen located at the slag dump site.
Results Achieved consistent production of 020mm aggregate at >180 TPH. Plant availability reached 94%, eliminating melt shop delays related to slag handling. The produced aggregate now generates a new revenue stream instead of incurring disposal fees.
Independent Aggregate Producer – Niche Market Expansion
Challenge An aggregate supplier sought entry into the industrial slag processing market but required guarantees their endproduct would meet strict environmental standards demanded by their readymix concrete clients.
Solution A midcapacity RoHS Compliant Slag Crusher Plant was selected specifically for its documented component compliance alongside high abrasion resistance.
Results The producer secured longterm contracts with two concrete batching plants requiring certified clean aggregates. The plant’s low wear rate resulted in operating costs comparable to processing natural granite.
7. KONSIDERATA TREGTARE
Nivelet e çmimeve janë të strukturuara rreth kapacitetit të xhiros dhe nivelit të automatizimit:
Konfigurimi i bazës (50100 TPH): Përfshin polic primar të nofullës, basic discharge conveyor, starterlevel control panel.
Konfigurimi standard (100200 TPH): Most common package featuring primary jaw + secondary cone/impact crusher integrated screening module PLC control automated lubrication
HighCapacity/Turnkey Configuration (200+ TPH): Includes all standard features plus comprehensive dust suppression advanced diagnostics telemetry capability extended walkways/service platforms
Karakteristikat opsionale:
Metal detector/magnet separator
Additional screening decks
Finished product washing module
Mbyllje për zbutjen e zërit
Paketat e Shërbimit:
Annual maintenance contracts provide scheduled inspections parts discounts priority technical support Financing Options Flexible arrangements including leasing capital equipment loans can be discussed based on project scope facilitating CAPEX planning
8. FAQ
Q1 Is the entire plant truly RoHS compliant including all subcomponents?
A1 Yes Our systems are supplied with full material declaration dossiers Major assemblies motors switchgear wiring hydraulic hoses etc are sourced from manufacturers who certify RoHS compliance providing you auditable documentation
Q2 Can this plant integrate with our existing material handling equipment?
A2 Absolutely Feed hoppers discharge heights conveyor speeds control interfaces can be engineered during design phase match your current yard layout transfer points ensuring smooth integration
Q3 What is typical installation timeline once equipment arrives on site?
A3 For a semi modular plant foundation preparation precedes delivery Mechanical erection electrical connection commissioning typically require weeks depending complexity Site civil works conducted concurrently minimize total project timeline
Q4 How does wear part pricing compare standard rock crushing equipment?
A4 While initial cost specialized liners jaws may higher their extended service life lower cost per ton processed Field data shows total annual expenditure wear parts often lower due reduced change out frequency labor savings
Q5 Çfarë trajnimi ofruan ekipet tona të mirëmbajtjes së operacioneve?
A5 Comprehensive training included covering safe normal operation routine maintenance checks troubleshooting procedures We provide detailed manuals conduct onsite sessions during commissioning ensure your team confident managing system
