1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Managing slag stockpiles presents persistent operational and financial challenges. Are you contending with inefficient manual breaking methods that bottleneck your material flow? Does inconsistent feed size from primary crushing reduce your downstream screening and separation efficiency, leading to valuable metal loss? Are you facing excessive wear on crusher components from abrasive slag, driving up maintenance costs and unplanned downtime? The costs of slow processing, high consumable expenses, and metal recovery inefficiency directly impact your site’s profitability. How can you transform this byproduct into a consistent, highvalue aggregate stream while controlling operational expenditure? The solution requires a purposeengineered system designed for the specific demands of slag reduction.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

A planta trituradora de escoria is a stationary or semimobile processing system engineered specifically for the size reduction of aircooled blast furnace (novio) escoria o escoria de acero. Its core function is to crush large slag lumps into precisely graded aggregates for use in construction, construcción de carreteras, or as a feedstock for further metal recovery processes.

Flujo de trabajo operativo:
1. Alimentar & Pre-selección: Slag is loaded via excavator or loader into a robust feed hopper, often with a grizzly section to bypass fine material.
2. Trituración Primaria: A heavyduty jaw crusher or impact breaker reduces large lumps (often up to 1m+) a un tamaño manejable.
3. Transferir & Trituración Secundaria: El material se transporta a una trituradora secundaria. (typically a cone crusher or impact crusher) for further refinement to the target product size.
4. Apresto & Separación: Crushed material passes through vibrating screens to separate it into specified fractions (p.ej., 05milímetros, 510milímetros, 1020milímetros). Magnetic separators are often integrated at this stage to extract remaining ferrous metal.
5. Almacenamiento: Los agregados clasificados se transportan a las reservas designadas para su envío..

Ámbito de aplicación: Ideal para plantas siderúrgicas integradas, patios de procesamiento de escoria independientes, y productores de áridos especializados en subproductos industriales.
Limitaciones: No diseñado para escoria fundida.; feed material must be aircooled and solid. Performance is contingent on proper feed size control and the specific abrasiveness and composition of the source slag.

3. CARACTERÍSTICAS PRINCIPALES

Configuración de trituradora de servicio pesado | Base técnica: Manganese steel jaws/liners with optimized crushing chamber geometry | Beneficio operativo: Sustained high throughput of highly abrasive material with reduced risk of premature failure | Impacto del retorno de la inversión: Lower costperton crushed via extended wear life and reduced frequency of liner changes.
Sistema integrado de recuperación de metales | Base técnica: Overband magnetic separators positioned at key discharge points | Beneficio operativo: Continuo, automated extraction of residual ferrous metal from the aggregate stream | Impacto del retorno de la inversión: Creates an additional revenue stream from recovered scrap metal while protecting downstream equipment from tramp metal damage.
Vibration Dampening Base Frame | Base técnica: Reinforced steel frame with antivibration mounts for major components | Beneficio operativo: Minimizes structural stress and transmitted vibration, ensuring stable operation and reducing foundation requirements | Impacto del retorno de la inversión: Lowers installation complexity and cost, enhances longterm structural integrity of the plant.
Engrase centralizado & Puntos de Monitoreo | Base técnica: Manifolded lubrication lines for all major bearing points | Beneficio operativo: Permite seguridad, efficient routine maintenance without requiring access to multiple isolated points during operation | Impacto del retorno de la inversión: Reduces lubrication time by up to 50%, promotes bearing health, and decreases unscheduled downtime.
Adjustable Discharge Setting System | Base técnica: Hydraulic or mechanical adjustment on secondary/tertiary crushers | Beneficio operativo: Allows operators to quickly change final product sizing to meet different market specifications | Impacto del retorno de la inversión: Enables rapid response to changing customer demands, maximizing plant utilization and sales opportunities.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Industry Standard Slag Processing | Nuestra solución de planta trituradora de escoria | Ventaja (% Mejora) |
| : | : | : | : |
| Rendimiento de tonelaje (Material abrasivo)| Variable, often declines with liner wear| Consistent output maintained via optimized wear part design & flow| Arriba a 1520% more consistent yield over liner life |
| Eficiencia de recuperación de metales| Singlestage magnetic separation, often manual cleaning| Multistage magnetic separation at optimal transfer points| Ferrous recovery rates improved by 2530% |
| Tiempo de inactividad por mantenimiento (Programado)| Dispersed lube points; manual setting adjustment| Centralized systems & hydraulic adjustment features| Routine service time reduced by approximately 40% |
| Consistencia de la forma del producto| Basic crushing circuits can produce flaky aggregates| Chamber optimization & crushing stage matching produces more cubical product| Improved cubicity index enhances aggregate value for premium applications |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 50 TPH por encima 300 TPH, depending on feed size and required product grading.
Requisitos de energía: La potencia total instalada normalmente oscila entre 150 kW a 600 kilovatios, supplied by mains connection or onboard diesel generator set for semimobile units.
Especificaciones de materiales: Primary wear components (revestimientos, impeller bars) manufactured from highchrome martensitic steel or premium manganese steel. Structural frames use heavyduty rolled steel sections.
Dimensiones físicas (Configuración típica): Footprint varies by capacity; a 150 TPH plant may require approximately 25m (l) x 18m (W.) x 12m (h).
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C. Dust suppression systems are standard to maintain environmental compliance.

6. ESCENARIOS DE APLICACIÓN

Integrated Steel Plant Slag Yard | Desafío: Inefficient primary breaking causing backlog; low recovery of valuable metallics from old slag dumps leading to lost revenue. | Solución: Deployment of a turnkey Slag Crusher Plant with highcapacity jaw crusher for primary reduction and two stages of magnetic separation. | Resultados: Processing rate increased to 180 TPH; recovered an average of 8 tons of ferrous metal per operating day; cleared legacy stockpile within projected timeline.

Commercial Aggregate Producer Specializing in Industrial Byproducts | Desafío: Existing plant struggled with extreme abrasiveness of steel slag, resulting in unsustainably high wear part costs and poor product shape limiting marketability.| Solución: Installation of a purposebuilt Slag Crusher Plant featuring specialized abrasionresistant liners and a cone crusher secondary stage for improved particle shape.| Resultados: Wear part lifecycle extended by over 60%; produced highquality cubical aggregate meeting road base specifications; opened access to highervalue construction contracts.

7. CONSIDERACIONES COMERCIALES

Our Slag Crusher Plants are offered in three primary tiers:
Configuración estándar: A robust base plant covering primary crushing, basic screening/conveying, and singlestage magnetic separation.
Configuración de recuperación mejorada: Adds secondary crushing for finer grading optimization and multistage magnetic separation drums/scanners.
Fully Modular/Mobile Configuration: Skidmounted or trailerbased units offering shorter installation times and relocation flexibility.

Optional features include automated dust suppression systems, advanced vibration monitoring sensors, paquetes de generación de energía a bordo, and custom conveyor lengths.

We provide comprehensive service packages ranging from annual inspection plans to fullturnkey operation & contratos de mantenimiento. Financing options including leasing structures are available through our partners to facilitate capital expenditure planning.

8. Preguntas frecuentes

1. Is your Slag Crusher Plant compatible with our existing conveyors and screening equipment?
Sí; our engineering team designs the transfer heights and discharge points based on your site layout survey data provided during quotation.

2. What is the expected operational impact on our power consumption?
Field data shows that an optimized plant design uses energy more efficiently per ton processed than piecemeal systems due to reduced recirculation loads.

3. How does pricing typically scale with capacity?
Pricing follows an economyofscale curve but is also influenced by specific requirements like level of metallurgical recovery needed or environmental enclosures.

4. ¿Cuáles son los términos comerciales estándar que se ofrecen??
We typically offer FOB pricing exworks alongside CIF quotations for international buyers; payment terms are structured around project milestones such as FAT (Prueba de aceptación de fábrica).

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