1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Managing slag from your steel, ferroalloy, 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. ¿Estás enfrentando estos desafíos??
High Disposal Costs & Liability: 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.
Tiempo de inactividad excesivo & Tener puesto: Standard crushers not built for abrasive slag suffer rapid wear part failure, causing frequent, costly production stops.
Salida inconsistente & Bottlenecks: An undersized or illconfigured crusher creates irregular feed size for downstream screening and sorting, limiting overall plant throughput.
Espacio & Logistics Constraints: Voluminoso, multistage crushing setups require excessive floor space and complicate material flow within a confined plant layout.

La pregunta central para los gerentes de planta es esta: how can you transform slag from a cost center into a recoverable asset while ensuring relentless, lowmaintenance operation?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

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.

Flujo de trabajo operativo:
1. Alimentar & Pre-selección: Runofplant slag is fed via loader or conveyor into an integrated grizzly or scalping screen to remove fine fractions and bypass noncrushable debris.
2. Reducción de tamaño primario: Oversize material is directed into the core impactor or jaw crusher module, applying high inertia to fracture slabs and liberate metallic inclusions.
3. Metal Separation & Descargar: Crushed material discharges onto a heavyduty discharge conveyor, typically passing over an overhead magnetic separator to extract liberated ferrous metal.
4. Trituración Secundaria (Opcional): For specific aggregate specifications, a secondary cone crusher module can be incorporated for precise cubical shaping.

Ámbito de aplicación: Designed for integrated steel plants, foundries, copper smelters, and ferroalloy producers processing blast furnace (novio) escoria, basic oxygen furnace (BOF) escoria, electric arc furnace (EAF) escoria, and nonferrous slags.

Limitaciones clave: 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. CARACTERÍSTICAS PRINCIPALES

Rotor de servicio pesado & Impact System | Base técnica: Highinertia rotor with monolithic manganese hammers/bimetal blow bars | Beneficio operativo: Sustains high impact energy against abrasive slag with minimal wear rate; handles occasional tramp metal without catastrophic failure | Impacto del retorno de la inversión: Reduces wear part change frequency by up to 40%, lowering direct parts cost and labor hours dedicated to maintenance.

Ajuste hidráulico & Claro | Base técnica: Integrated hydraulic cylinders for apron positioning and crusher housing opening | Beneficio operativo: Allows operators to adjust product gradation in minutes and clear blockages safely without manual entry into the crushing chamber | Impacto del retorno de la inversión: Eliminates hours of dangerous manual labor per blockage event; enables quick optimization for varying feed materials.

AbrasionResistant Lining System | Base técnica: Bolton wear liners made of AR400/500 steel in highwear zones | Beneficio operativo: Protects the crusher’s structural frame from abrasion, preserving its longterm integrity and preventing costly structural repairs | Impacto del retorno de la inversión: Extends the service life of the main chassis by years, protegiendo su inversión de capital.

Alimentador Grizzly integrado | Base técnica: Steppededge vibrating grizzly feeder with adjustable spacing | Beneficio operativo: Removes subsize material before crushing (increasing effective capacity) and evenly distributes feed across full rotor width for uniform wear | Impacto del retorno de la inversión: Increases total plant throughput by preventing chokefeeding of fines; extends wear part life through even distribution.

PLCBased Control & Escucha | Base técnica: Centralized control panel with PLC featuring amp draw monitoring, bearing temperature sensors, and vibration detection points | Beneficio operativo: Provides realtime operational data to prevent overload conditions; enables predictive maintenance scheduling based on actual load data | Impacto del retorno de la inversión: Prevents major component failures; allows maintenance planning during scheduled stops.

Modular Base Frame Design | Base técnica: Preassembled crusher module mounted on a unified heavyduty support frame | Beneficio operativo: Simplifies foundation requirements and reduces onsite assembly time during installation; allows for future reconfiguration or relocation | Impacto del retorno de la inversión: Cuts installation costs by approximately 25% and minimizes plant commissioning downtime.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Solución estándar de la industria | Our Commercial Slag Crusher Plant Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Desgaste parte de la vida (Barras de golpe/martillos) | Manganese Steel Castings | Proprietary BiMetal Alloy Castings / Ceramic Composite Liners Optional| +3550% longer operational life |
| 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 horas de funcionamiento <8% capacity drop over 100 horas de funcionamiento +47% more stable output |
| Unplanned Downtime Due to Blockages Average 812 hours per month Average 50% reduction in blockagerelated stops |
| Costo total de propiedad (5Year Estimate) Based on parts + mano de obra + downtime Based on our field data analysis Estimated 2030% más bajo |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 50 a más 600 toneladas métricas por hora (TPH), depending on feed size and desired product specification.
Requisitos de energía: Motores de accionamiento primario de 150 kW a 450 kilovatios; total plant power dependent on configuration (comederos, transportadores).
Feed Size Maximum: Up to 1000mm x 1200mm slab handling capability (dependiente del modelo).
Product Size Range: Adjustable from 150mm down to 40mm in primary configuration; finer sizes achievable with secondary circuit.
Especificaciones clave de materiales: 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.
Dimensiones físicas (Typical Primary Module): Approximately L12m x W4m x H5m. Foundation loads provided per project.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C; dust suppression system connections standard.

6. ESCENARIOS DE APLICACIÓN

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. CONSIDERACIONES COMERCIALES

Our Commercial Slag Crusher Plants are offered in three primary tiers:
1. Standard Duty Plant: Para menor tonelaje (<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.Preguntas frecuentes

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