1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Managing slag byproduct is a persistent operational bottleneck with tangible costs. ¿Estás enfrentando estos desafíos??
Alto tiempo de inactividad para trituradoras primarias: Uncrushed slag with oversized metal inclusions causes frequent jams in primary crushers, leading to hours of unplanned maintenance and lost processing time.
Manejo de materiales ineficiente & Clasificación: 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, pantallas, y trituradoras secundarias.
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.

La pregunta central para los gerentes de planta es: ¿Cómo se puede transformar un costoso flujo de residuos en un flujo controlado?, profitable material flow while protecting your core crushing circuit?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

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, fundiciones, and metal production facilities. Its design prioritizes the handling of abrasive, heterogeneous material containing metallic inclusions.

Flujo de trabajo operativo:
1. Alimentar & Pre-selección: Runoffurnace slag is fed via loader into a robust hopper, often with a grizzly section to bypass subsize material.
2. Primary Liberation Crushing: La trituradora de núcleos (típicamente un tipo de mandíbula o impacto) aggressively reduces the slag mass, breaking it apart to liberate embedded metallic components.
3. Separación de metales & Extracción: El material triturado pasa por un separador magnético elevado. (suspended magnet or magnetic pulley), which automatically extracts ferrous scrap for recovery.
4. Apresto & Almacenamiento: The separated aggregate fraction is conveyed to a primary stockpile or directly to a secondary screening circuit for further grading.

Ámbito de aplicación: Ideal para plantas siderúrgicas integradas, patios de procesamiento de escoria independientes, and aggregate producers specializing in secondary materials. Best suited for ferrous slag (BOF, EAF). Performance on nonferrous slags requires specific configuration.

Limitaciones: 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. CARACTERÍSTICAS PRINCIPALES

Alimentador Grizzly de servicio pesado | Base técnica: Preselección & alimentación regulada | Beneficio operativo: Removes fines prior to crushing and ensures a consistent, controlled feed rate to the crusher chamber | Impacto del retorno de la inversión: Increases crusher throughput by up to 15% and reduces wear on crusher liners

Reinforced Jaw Crusher Chamber | Base técnica: High manganese steel liners & ángulo de contacto optimizado | Beneficio operativo: Withstands extreme abrasion and shock loads from uncrushable metals; hydraulic toggle adjustment allows quick setting changes | Impacto del retorno de la inversión: Reduces liner replacement frequency by ~30% versus standard configurations

Integrated Overband Magnetic Separator | Base técnica: Permanent magnet or electromagnetic circuit mounted over discharge conveyor | Beneficio operativo: Automatically extracts liberated ferrous scrap continuously during operation without stopping the process flow | Impacto del retorno de la inversión: Capturas 95%+ de metal recuperable, creating a direct revenue stream from waste

Engrase centralizado & Sistema hidráulico | Base técnica: Singlepoint lubrication lines for key bearings and hydraulic controls for adjustment/clearing | Beneficio operativo: Permite seguridad, routine maintenance in under 30 minutos; allows operators to clear blockages remotely | Impacto del retorno de la inversión: Cuts planned maintenance time by half and minimizes personnel exposure to equipment internals

CE Certified Safety Guards & Plataformas de acceso | Base técnica: Full compliance with EU Machinery Directive 2006/42/EC | Beneficio operativo: Proporciona seguridad, compliant access for inspection and maintenance; interlocks prevent operation during servicing | Impacto del retorno de la inversión: Mitigates risk of regulatory noncompliance fines and reduces workplace incident potential

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Basic Crushing) | CEMarked Slag Crusher Plant Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Tasa de recuperación de metales | Recolección manual posttrituración (~7080%) | Continuous automated extraction during process (>95%)| +20% Eficiencia de recuperación |
| Crusher Downtime due to Tramp Metal| 812 hours per month for clearing/repair| Menos que 2 hours per month with hydraulic clearing| ~80% Reduction in Unplanned Stops |
| Liner Life in Abrasive Service| Aprox.. 60,000 toneladas por juego| Aprox.. 85,000 toneladas por juego (reinforced)| ~40% Longer Service Life |
| Consistencia del proceso (Control de alimentación)| Manual loader feeding (variable)| comedero para grizzly + regulated flow (coherente)| Throughput stability improved by ~25% |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 50 a 400 toneladas por hora.
Opciones de trituradora primaria: Cursor de mandíbula (models from 750x500mm to 1200x1000mm) or Impact Crusher with hydraulic adjustment.
Requisitos de energía: Potencia total instalada normalmente entre 90 kilovatios 250 kilovatios, dependiente de la configuración (400V/50Hz standard).
Especificaciones clave de materiales:
Revestimientos de trituradora: AR400 / Hardox steel or premium manganese steel.
Cinta transportadora: Minimum EP400/3 with abrasionresistant covers.
Marco estructural: Heavyduty welded sections from S355JR steel.
Dimensiones físicas (Configuración típica): Approximate footprint of 20m L x 8m W x 7m H. Designed for flat concrete foundation.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 10°C a +45°C. Dust suppression spray bars are fitted as standard at transfer points.

6. ESCENARIOS DE APLICACIÓN

Integrated Steel Mill – BOF Slag Processing | Desafío: 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.| Solución: Installation of a CEMarked Slag Crusher Plant with a heavyduty jaw crusher and powerful overband magnet at the slag tipping point.| Resultados: 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.

Contratista independiente de procesamiento de escoria | Desafío: A contractor needed to process varying stockpiles of EAF slag at multiple sites but required compliance with EU site safety regulations.| Solución: A semimobile skidmounted CEMarked Slag Crusher Plant was selected.| Resultados: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. CONSIDERACIONES COMERCIALES

Our CEMarked Slag Crusher Plants are offered in three primary tiers:
Planta de servicio estándar: For lowervolume operations (<100tph). Incluye trituradora de mandíbulas central.,imán,y transportador de descarga básico.
Planta de servicio pesado: For highvolume steel mills (>200tph). Features reinforced impactor option,alimentador vibratorio grizzly,and multiple magnetic separation stages.
SemiMobile Skid Plant: For multisite contractors.All core components mounted on heavyduty skidsfor transportability.

Las características opcionales incluyen:

• Secondary screening unit
• Advanced dust suppression system
• Metal fragmentizer attachment
• Paquete telemático de monitorización remota

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,y estructuras de alquiler.

8.Preguntas frecuentes

Q1.¿Es esta planta compatible con nuestro sistema transportador existente??
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,lubricantes,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(revestimientos de trituradora)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