Slag Crusher Plant Producers Design Service
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??
Përçueshmëri jo e besueshme & Koha e ndërprerjes: Inconsistent feed size and tramp metal cause frequent jams in standard crushers, halting your entire material recovery line and delaying downstream processing.
Veshja e tepërt & Shpenzimet e Mirëmbajtjes: 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.
Pluhuri & 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: si arrini të qëndrueshme, highvolume slag reduction with lower operational costs and maximized metal recovery? Përgjigja qëndron në një qëllim të projektuar Impianti i Thërrmuesit të Skorjeve.
2. PËRMBLEDHJE E PRODUKTIT
A Impianti i Thërrmuesit të Skorjeve is a stationary or semimobile processing system specifically engineered for the primary, dytësore, dhe nganjëherë thërrmimi terciar i skorjeve metalurgjike (furra shpërthyese, furre çeliku, bakri, etj.). Its design prioritizes durability against abrasion and impact while ensuring efficient liberation of entrapped metals.
Rrjedha e punës operative:
1. Feed & Para-Screening: Runofpile slag is fed via loader or conveyor into a vibrating grizzly feeder, which removes fine fractions (30mm) për të anashkaluar thërrmuesin primar, increasing system efficiency.
2. Thërrmimi primar: Oversize material is reduced by a heavyduty jaw crusher or impactor designed for high compressive strength feed.
3. Ndarja e metaleve & Thërrmimi sekondar: 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 (p.sh., 20mm).
4. Përmasat & Grumbullimi i rezervave: A final vibrating screen classifies the product, me material të madh të riqarkulluar. Onspec material is conveyed to stockpile for sale as aggregate or for further processing.
Fusha e Aplikimit: Ideale për fabrikat e integruara të çelikut, shkritoret, kantieret e përpunimit të skorjeve, and aggregate producers handling ferrous and nonferrous slags.
Kufizimet: Not designed for primary mining of virgin rock or for processing materials with extreme moisture or clay content without preconditioning.
3. TIPARET THEMELORE
Ushqyes Grizzly vibrues HeavyDuty | Baza Teknike: Highstrength eccentric shaft drive | Përfitimi Operacional: Removes fines upfront, regulates feed to the primary crusher preventing chokefeeding | Ndikimi i ROI: Reduces primary crusher load by up to 30%, lowering wear and energy consumption per ton processed.
AbrasionResistant Liner Packages | Baza Teknike: Airhardening manganese steel or composite ceramic/metal alloys | Përfitimi Operacional: Jetëgjatësia e linjës është zgjatur me 4060% compared to standard manganese in highabrasion zones | Ndikimi i ROI: Decreases downtime for liner changes and reduces annual spare parts inventory cost.
Qarku i integruar magnetik i ndarjes | Baza Teknike: Magnet vetëpastrues mbi brez të pozicionuar në pikat optimale të shkarkimit | Përfitimi Operacional: Continuously extracts liberated ferrous metal during crushing stages | Ndikimi i ROI: Creates a direct revenue stream from scrap recovery and protects downstream conveyors and crushers from metal damage.
Grasimi i centralizuar & Sistemet Hidraulike | Baza Teknike: Automated lubrication points for bearings and hydraulic adjustment/tramp release systems | Përfitimi Operacional: Ensures critical components are lubricated under all operating conditions; allows quick clearing of uncrushables | Ndikimi i ROI: Parandalon dështimet katastrofike të kushinetës (a major cause of downtime) and minimizes manual maintenance intervention time.
Integrimi i Sistemit të Shtypjes së Pluhurit | Baza Teknike: Vargjet e hundës në pikat e transferimit të lidhura me furnizimin me ujë me komandim solenoid | Përfitimi Operacional: Effectively controls dust emissions at source during crushing operations | Ndikimi i ROI: Zbut rreziqet e mospërputhjes mjedisore dhe zvogëlon kostot e punës për mbajtjen e shtëpisë.
Robust Structural Fabrication | Baza Teknike: Stiffened frame design with heavyduty crawler or fixed plant support legs | Përfitimi Operacional: Maintains alignment under continuous highvibration loads over years of operation | Ndikimi i ROI: Eliminates costly structural repairs and prevents premature failure of mounted components due to frame flexing.
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Zgjidhja standarde e industrisë | Zgjidhja jonë e impiantit të thërrmuesit të skorjeve | Avantazhi (% përmirësim) |
| : | : | : | : |
| Disponueshmëria / Koha e funksionimit | 8085%, frequent jamming from tramp metal >8592%, hydraulic tramp release clears uncrushables in 8% rriten |
| Liner Life në Fazën Fillore (Mn çeliku) ~40,000 MT throughput ~60,000 MT throughput >50% përmirësim |
| Specific Power Consumption ~0.8 1.0 kWh/ton ~0.65 0.75 kWh/ton >20% reduktim |
| 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. SPECIFIKIMET TEKNIKE
Gama e Kapacitetit: I konfigurueshëm nga 50 TPH deri në fund 300 skorje e përpunuar TPH.
Kërkesat për fuqi: Fuqia totale e instaluar zakonisht varion nga 150 kW (për 50 Uzina TPH) te 450 kW (për 300 Uzina TPH), në varësi të konfigurimit.
Specifikimet e materialit: Primary crusher jaws/liners manufactured from premiumgrade Manganese Steel (1822%). Critical wear plates utilize AR400 steel. Structural frames fabricated from heavyduty ISMC/ISMB sections.
Dimensionet fizike (Tipike 150 Uzina TPH): Gjatësia (~ 25 m) x Gjerësia (~ 8 m) x Lartësia (~ 7 m). Available in fixed skidmounted or semimobile trailer versions.
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 20°C deri në +50°C. Sistemi i frenimit të pluhurit kërkon furnizim me ujë të pastër në 3040 PSI; consumption approx. 50 liters per ton crushed.
6. Skenarët e APLIKIMIT
Integrated Steel Plant Slag Yard Challenge:
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.
Zgjidhje:
Zbatimi i një çelësi në dorë Impianti i Thërrmuesit të Skorjeve 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.
Rezultatet:
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 (3mm), rendering gravity separation ineffective.
Zgjidhje:
A twostage Impianti i Thërrmuesit të Skorjeve using a jaw crusher followed by a cone crusher in closed circuit with a screen was deployed for controlled size reduction targeting 12mm+3mm.
Rezultatet:
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. KONSIDERATA TREGTARE
Nivelet e çmimeve: Solutions are projectspecific but generally fall into three categories:
Standard SkidMounted Plant (50100 TPH): A costeffective entry point for lower volume processors.
Modular MediumCapacity Plant (100200 TPH): The most common configuration offering optimal balance of output and investment.
HighCapacity Fixed Stationary Plant (200300+ TPH): Designed for largescale producers requiring maximum uptime and automation.
Karakteristikat opsionale: Vibrating feeder vs apron feeder; secondary cone vs impact crusher; automated metal detection system; advanced PLC control panels with remote monitoring capability; rrethime zanore.
Paketat e Shërbimit: Planet e garancisë së zgjatur; kontratat vjetore të inspektimit; guaranteed spare parts delivery schedules (p.sh., 48hour critical parts availability).
Opsionet e financimit: Strukturat e dhënies me qira të pajisjeve nëpërmjet institucioneve financiare partnere; 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. Cili është niveli i pritshëm i zhurmës operacionale?
With standard equipment enclosures, matjet në terren zakonisht tregojnë nivelet më poshtë 85 dB(A) at a distance of one meter from the machinery when processing dry slag.
3. Sa kohë zgjat instalimi?
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.Mund të jepni garanci për performancën?
Yes we offer guaranteed minimum throughput capacity based on defined feed material characteristics as well as maximum power consumption per ton
5.What are typical payment terms?
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
