1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Quản lý xỉ từ thép của bạn, hợp kim sắt, or nonferrous metal production is a persistent operational bottleneck. Inefficient processing directly impacts your bottom line through high handling costs, lost revenue from unrecovered metallics, and unplanned maintenance downtime. Bạn có đang phải đối mặt với những thách thức này?
Chi phí xử lý cao & Trách nhiệm pháp lý: Transporting and landfilling untreated slag consumes significant budget and creates longterm environmental liability.
Unrecovered Metal Loss: Ineffective crushing leaves valuable metallics locked in slag, representing direct revenue loss per ton processed.
Thời gian ngừng hoạt động quá mức & Mặc: Standard crushers not built for abrasive slag suffer rapid wear part failure, causing frequent, costly production stops.
Đầu ra không nhất quán & Bottlenecks: An undersized or illconfigured crusher creates irregular feed size for downstream screening and sorting, limiting overall plant throughput.
Không gian & Những hạn chế về hậu cần: Bulky, multistage crushing setups require excessive floor space and complicate material flow within a confined plant layout.

Câu hỏi trọng tâm đối với các nhà quản lý nhà máy là đây: how can you transform slag from a cost center into a recoverable asset while ensuring relentless, lowmaintenance operation?

2. TỔNG QUAN SẢN PHẨM

Our Commercial Slag Crusher Plant is a heavyduty, stationary processing system engineered specifically for the continuous reduction of aircooled or granulated metallurgical slag. It is designed to liberate encapsulated metal for maximum recovery and produce a consistently sized aggregate product for commercial sale.

Quy trình hoạt động:
1. Cho ăn & Sàng lọc trước: Runofplant slag is fed via loader or conveyor into an integrated grizzly or scalping screen to remove fine fractions and bypass noncrushable debris.
2. Giảm kích thước chính: Oversize material is directed into the core impactor or jaw crusher module, applying high inertia to fracture slabs and liberate metallic inclusions.
3. Tách kim loại & Phóng điện: Crushed material discharges onto a heavyduty discharge conveyor, typically passing over an overhead magnetic separator to extract liberated ferrous metal.
4. Nghiền thứ cấp (Không bắt buộc): For specific aggregate specifications, a secondary cone crusher module can be incorporated for precise cubical shaping.

Phạm vi ứng dụng: Designed for integrated steel plants, xưởng đúc, lò luyện đồng, and ferroalloy producers processing blast furnace (bạn trai) xỉ, lò oxy cơ bản (BOF) xỉ, electric arc furnace (EAF) xỉ, and nonferrous slags.

Hạn chế chính: Not designed for primary rock mining applications or processing unsorted demolition debris with excessive tramp metal. Feed size must comply with crusher opening specifications.

3. TÍNH NĂNG CỐT LÕI

Cánh quạt hạng nặng & Impact System | Cơ sở kỹ thuật: Highinertia rotor with monolithic manganese hammers/bimetal blow bars | Lợi ích hoạt động: Sustains high impact energy against abrasive slag with minimal wear rate; handles occasional tramp metal without catastrophic failure | Tác động ROI: Reduces wear part change frequency by up to 40%, lowering direct parts cost and labor hours dedicated to maintenance.

Điều chỉnh thủy lực & Thanh toán bù trừ | Cơ sở kỹ thuật: Integrated hydraulic cylinders for apron positioning and crusher housing opening | Lợi ích hoạt động: Allows operators to adjust product gradation in minutes and clear blockages safely without manual entry into the crushing chamber | Tác động ROI: Eliminates hours of dangerous manual labor per blockage event; enables quick optimization for varying feed materials.

AbrasionResistant Lining System | Cơ sở kỹ thuật: Bolton wear liners made of AR400/500 steel in highwear zones | Lợi ích hoạt động: Protects the crusher’s structural frame from abrasion, preserving its longterm integrity and preventing costly structural repairs | Tác động ROI: Extends the service life of the main chassis by years, bảo vệ vốn đầu tư của bạn.

Bộ nạp Grizzly tích hợp | Cơ sở kỹ thuật: Steppededge vibrating grizzly feeder with adjustable spacing | Lợi ích hoạt động: Removes subsize material before crushing (increasing effective capacity) and evenly distributes feed across full rotor width for uniform wear | Tác động ROI: Increases total plant throughput by preventing chokefeeding of fines; extends wear part life through even distribution.

Điều khiển dựa trên PLC & Giám sát | Cơ sở kỹ thuật: Centralized control panel with PLC featuring amp draw monitoring, bearing temperature sensors, and vibration detection points | Lợi ích hoạt động: Provides realtime operational data to prevent overload conditions; enables predictive maintenance scheduling based on actual load data | Tác động ROI: Prevents major component failures; allows maintenance planning during scheduled stops.

Modular Base Frame Design | Cơ sở kỹ thuật: Preassembled crusher module mounted on a unified heavyduty support frame | Lợi ích hoạt động: Simplifies foundation requirements and reduces onsite assembly time during installation; allows for future reconfiguration or relocation | Tác động ROI: Giảm chi phí lắp đặt khoảng 25% and minimizes plant commissioning downtime.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Giải pháp tiêu chuẩn ngành | Our Commercial Slag Crusher Plant Solution | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Mặc một phần cuộc sống (Thanh thổi/búa) | Manganese Steel Castings | Proprietary BiMetal Alloy Castings / Ceramic Composite Liners Optional| +3550% tuổi thọ hoạt động lâu hơn |
| Metal Liberation Efficiency (Ferrous Recovery) ~90% liberation rate postcrush >95% liberation rate postcrush +57% increase in recovered metal yield |
| Throughput Consistency Under Abrasive Feed ~15% capacity drop over 100 giờ hoạt động <8% capacity drop over 100 giờ hoạt động +47% more stable output |
| Unplanned Downtime Due to Blockages Average 812 hours per month Average 50% reduction in blockagerelated stops |
| Tổng chi phí sở hữu (5Year Estimate) Based on parts + nhân công + downtime Based on our field data analysis Estimated 2030% thấp hơn |

5. THÔNG SỐ KỸ THUẬT

Phạm vi công suất: Có thể cấu hình từ 50 đến hơn 600 tấn mỗi giờ (TPH), depending on feed size and desired product specification.
Yêu cầu về nguồn điện: Primary drive motors from 150 kW để 450 kW; total plant power dependent on configuration (người cho ăn, băng tải).
Kích thước nguồn cấp dữ liệu tối đa: Up to 1000mm x 1200mm slab handling capability (phụ thuộc vào mô hình).
Phạm vi kích thước sản phẩm: Adjustable from 150mm down to 40mm in primary configuration; finer sizes achievable with secondary circuit.
Thông số kỹ thuật vật liệu chính: Mainframe fabrications from heavyduty steel plate; Rotor shaft forged alloy steel; Bearings rated for high shock loads; Wear components in premium manganese or chromium iron alloys.
Kích thước vật lý (Typical Primary Module): Approximately L12m x W4m x H5m. Foundation loads provided per project.
Phạm vi hoạt động môi trường: Được thiết kế cho nhiệt độ môi trường xung quanh từ 20°C đến +45°C; dust suppression system connections standard.

6. KỊCH BẢN ỨNG DỤNG

Integrated Steel Plant – BOF Slag Processing

Challenge A major steel producer faced escalating landfill costs for BOF slag and needed to recover contained scrap metal more efficiently. Their existing jaw crusher suffered constant liner wear and poor metal liberation.
Solution Implementation of a highinertia impactortype Commercial Slag Crusher Plant with an integrated magnetic head pulley on the discharge conveyor.
Results Metal recovery increased by 6%. The consistent 80mm output improved downstream screening efficiency by 15%. Wear part costs decreased by an estimated $18,000 annually due to longer service intervals.

Ferrochrome Smelter – Lump Slag Aggregate Production

Challenge A smelter required a reliable method to process large lumps of aircooled ferrochrome slag into a saleable construction aggregate. Throughput was limited by frequent jamming in their old compressionstyle crusher.
Solution Installation of a grizzlyfed impact crusher plant with hydraulic adjustment and clearing capabilities specifically configured for highly abrasive ferrochrome slag.
Results The plant achieved a steady throughput of 180 TPH without blockages. The hydraulic system enabled quick product size adjustments between rail ballast and road base specifications. Aggregate sales now offset over onethird of the site’s raw material handling costs.

7. CÂN NHẮC THƯƠNG MẠI

Our Commercial Slag Crusher Plants are offered in three primary tiers:
1. Nhà máy làm nhiệm vụ tiêu chuẩn: For lower tonnage (<150 TPH) or intermittent use applications processing less abrasive slags like some nonferrous varieties.
2. HeavyDuty Plant: Our most common configuration for continuous operation in EAF/BOF steel mills at midrange capacities (150400 TPH), featuring standard abrasion packages.
3. UltraDuty Plant: Engineered for maximum abrasion resistance (>400 TPH) in severe applications like stainless steel or highly abrasive alloy slags, featuring premium wear materials throughout.

Optional features include secondary/tertiary crushing modules automated metal sorting systems advanced dust suppression packages extended remote monitoring service contracts

Financing options are available including capital lease operating lease project financing terms tailored to match your cash flow requirements

8.Câu hỏi thường gặp

Q What are my foundation requirements?
A We provide detailed foundation drawings specific to your ordered model Our modular base frame design simplifies civil work but requires a solid reinforced concrete pad designed by your contractor based on our load data

Q How does this integrate with my existing conveyors screens?
A Our engineering team will review your current layout feed points discharge heights The crusher plant is designed with standard conveyor interfaces We can specify necessary chutes transfer points as part of the scope

Q What is the expected operational availability?
A When maintained according to our schedule field data shows operational availability exceeding92 excluding planned maintenance stops This is due primarilyto the robust designand predictive monitoring systems

Q Can you provide performance guarantees?
A Yes we offer guaranteed minimum throughput capacity based on agreed feed material specificationsand product size as well as maximum power consumption under load These are detailed in commercial proposals

Q What does the typical service package include?
A Our recommended package includes scheduled inspections remote monitoring support annual bearing grease analysisand guaranteed priority shipmentof criticalwear parts This structured approach maximizes uptime

Q How long does installation take?
A Fora standard heavy dutyplantwith preassembled modules onsite mechanical erection typically requires1014 dayswith an experienced crew Electrical connectionand commissioning add further time dependenton site readiness