1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

La gestión de escorias es un cuello de botella persistente con costes tangibles. ¿Se enfrenta a estos desafíos operativos??
Rendimiento poco confiable: Inconsistent crusher performance creates pileup at the furnace or converter, delaying tapping schedules and disrupting upstream production.
Tiempo de inactividad excesivo: Fallos mecánicos frecuentes, particularly from uncrushable tramp metal or abrasive materials, lead to unscheduled maintenance, altos costos de reemplazo de piezas, and lost processing hours.
Altos costos operativos: Desgaste prematuro de los martillos., revestimientos, and rotors from highimpact crushing drives a continuous cycle of consumable expenditure and labor for changes.
Seguridad & Peligros de limpieza: Dust generation during crushing and the handling of jagged, oversized slag fragments pose risks to personnel and create a problematic worksite environment.
Inflexible Output: Inability to adjust final product size efficiently limits your ability to meet specific grading requirements for different recycling or aggregate applications.

La pregunta central para los gerentes de planta es: how can you transform slag from a costly byproduct into a reliable, revenuegenerating stream without compromising primary production?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO: ODM SLAG CRUSHER PLANT

An ODM (Fabricante de diseño original) Slag Crusher Plant is a customengineered, stationary or semimobile processing system designed specifically for the reduction of metallurgical slag. Unlike standard offtheshelf crushers, an ODM plant is fabricated based on your specific slag analysis, capacidad requerida, y limitaciones del sitio.

Flujo de trabajo operativo:
1. Alimentar & Pre-selección: Slag from the ladle or stockpile is fed via apron feeder or conveyor. An initial grizzly section removes fine material bypassing the crusher.
2. Reducción de tamaño primario: La trituradora de núcleos (typically a robust impactor or jaw crusher) accepts large chunks (hasta 1m+) and reduces them to a manageable size (p.ej., <200milímetros).
3. Tramp Metal Separation: A critical stage where an overhead magnetic separator removes ferrous tramp metal after primary crushing but antes trituración secundaria, protegiendo el equipo aguas abajo.
4. Trituración Secundaria & Cribado: A secondary crusher (often a cone or impactor) further reduces material, which is then screened into specified product fractions (p.ej., 010milímetros, 1040milímetros).
5. Almacenamiento & Despacho: Sized products are conveyed to designated stockpiles for loading out.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal para plantas siderúrgicas integradas, fundiciones de cobre/níquel, and ferrous alloy producers processing aircooled blast furnace (novio) escoria, escoria de horno de acero (BOF/EAF), and nonferrous slags with manageable metal content.
Limitaciones: No diseñado para el manejo de escoria fundida.. Performance is contingent on accurate feed material analysis; slags with extremely high metallic yield or tenacious composite materials may require pretreatment or specific crusher configurations.

3. CARACTERÍSTICAS PRINCIPALES

Conjunto de rotor de servicio pesado | Base técnica: Forged steel rotor discs with highinertia design | Beneficio operativo: Sustains higher kinetic energy for effective breakage of dense slag lumps with less wear per ton processed | Impacto del retorno de la inversión: Reduced specific power consumption (kWh/tonelada) and longer intervals between rotor service.

Ajuste hidráulico & Protección contra sobrecarga | Base técnica: Integrated hydraulic cylinders for setting adjustment and automatic release upon uncrushable object entry | Beneficio operativo: Operators can adjust product size settings quickly under load; system protects itself from severe damage by tramp metal | Impacto del retorno de la inversión: Minimizes risk of catastrophic failure events that cause days of downtime.

Sistema de revestimiento resistente a la abrasión | Base técnica: Bolton liner plates manufactured from proprietary AR steel alloys (400500+ Brinell) in optimized wear zones | Beneficio operativo: Liners withstand extreme abrasion from crystalline slag structure, extending service life in highwear areas like impact aprons and breaker plates | Impacto del retorno de la inversión: Lowers total cost of ownership through fewer liner changeouts and associated labor.

Enclosed Housing with Dust Extraction Ports | Base técnica: Sealed crusher housing engineered with strategically placed flanges for connection to plant dust suppression or collection systems | Beneficio operativo: Significantly contains dust generated at primary impact points, mejorar la visibilidad del sitio y la calidad del aire | Impacto del retorno de la inversión: Reduces housekeeping costs and supports compliance with workplace environmental standards.

Pasarela Modular & Acceso de mantenimiento | Base técnica: Integrated platforms, escaleras, and pullout sections designed around major service points (rotor, revestimientos) per maintenance procedure study | Beneficio operativo: Technicians perform routine inspections, cambios de revestimiento, and major overhauls safely and efficiently with correct tool access | Impacto del retorno de la inversión: Reduce el tiempo de inactividad por mantenimiento planificado hasta en 30% based on field data comparisons.

Engrase centralizado & Puntos de monitoreo de condición | Base técnica: Manifolded lubrication lines routing from central stations to all key bearings; provision for sensor (vibración,temperatura) instalación | Operational Benefit Ensures consistent bearing lubrication critical in highshock environments; enables predictive maintenance protocols| ROI Impact Prevents bearing seizure failures extends component life reduces unplanned stoppages

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Solución estándar de la industria | ODM Slag Crusher Plant Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad (%)| 8085% (downtime for wear changes/breakdowns)| 9295% (designformaintenance access + sistemas de protección)| +10% tiempo de actividad operativa |
| Etapa primaria de vida útil del revestimiento (Horas)| ~500600 hrs on abrasive BF slag| ~750900 hrs via optimized alloy/design| +40% llevar vida |
| Eventos de daños por metales atrapados| 23 significant incidents/year average| 80% reduction in related repairs |
| Consumo de energía específico| Benchmark varies; typically higher due to inefficient reduction| Lower kWh/ton via highinertia rotor & optimal chamber geometry| Los datos de campo muestran 812% mejora |
| Consistencia del rendimiento (±%)| +/ 15% variance due to bridging/wear performance decay|< +/ 5% variance via controlled feed & adaptive crushing action| More predictable downstream process flow |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 150 TPH por encima 600 TPH, based on feed characteristics and required product sizing.
Requisitos de energía: El accionamiento de la trituradora primaria normalmente oscila entre 250 kW a 500 kilovatios, dependent on model capacity; La carga total conectada a la planta incluye transportadores., pantallas,and auxiliaries.
Especificaciones de materiales:
Crusher housing/frame: Heavyduty structural steel plate (>25mm in stress areas).
Wear components: Manganese steel or chromium carbide overlays for hammers/impactor bars; AR plate liners (>400 BHN).
Rotor shaft material: Forja de acero aleado (p.ej., 34CrNiMo6), probado ultrasónicamente.
Dimensiones físicas: Footprint is projectspecific; a typical primary/secondary skidmounted module may measure approximately (l)20m x (W.)8m x (h)7metro.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C, with optional features for dust sealing (IP65 on bearings)and highhumidity environments common in mill settings.

6. ESCENARIOS DE APLICACIÓN

Integrated Steel Plant Blast Furnace Slag Processing

Desafío: A major steel producer faced frequent plugging and accelerated wear in their existing hammer mill circuit when processing coarse blast furnace slag containing occasional skulls.The resulting downtime was delaying hot slag pit clearing.
Solución: Implementation of an ODM Slag Crusher Plant featuring a deepchamber primary jaw crusher followed by an overhead magnetic separatorand secondary horizontal shaft impactor.The jaw's linear compression action effectively broke the tough skulls without stalling
Resultados: Throughput stabilized at 400 TPH.Plant availability increased from ~78%to93%.Wear costs on primary stage reduced by60%due to the jaw's more abrasionresistant plate design

Copper Smelter Recycling Converter Slag

Desafío: The client neededto liberateand recover entrained copper mattefrom lump converter slag while producinga consistentminus50mm aggregatefor construction sales Existing equipment struggledwith varying feed hardnessand caused excessive fines generation
Solución: A twostage ODM plant was configuredwitha primary impactcrusheroperatingin closed circuitwitha screen This allowedfor controlledimpactbreakingfor bettermetalliberationand recirculationof oversize
Resultados: Matte liberation efficiency improved allowingfor highermetal recovery ratesin downstreamprocessing Aggregateproduct cubicity met premiumspecifications enablinga20%increasein salesprice Fines generationwas reducedby15%

7.CONSIDERACIONES COMERCIALES

ODM Slag Crusher Plants are capital investments priced accordingto capacity complexityand material specifications

Niveles de precios
– Base Configuration Skidmountedprimarycrushingmodulewith basic discharge conveyor Starting point formajor projects
– StandardizedPlant Includesprimarycrusher magnetic separator secondarycrusherscreen moduleand controlpanel The most commonturnkeysolution
– Fully CustomizedSystem Engineeredfor complexlayouts multipleproductsizes automatedmaterialhandlingandsophisticatedcontrols

Optional Features include advanced condition monitoring systems automated grease systems speciallinermaterials forextreme abrasion dust suppression cannon integrationand sound attenuation enclosures

Service Packages typicallycompriseawarrantyperiod followedby annualmaintenancecontracts offering scheduledinspections priorityparts supplyand experttechnical support Financing options suchas equipment leasingor project financingare often availablethroughpartner institutions tomatchcapitalexpendituretothe asset'sproduction lifecycle

Preguntas frecuentes

Q1 Is an ODM plant compatible with our existing material handling system?
A Yes A core principleofODM fabricationis interfaceengineering We designfeedand discharge points conveyor heightsand control integrationtomatchyour currentlayout minimizingcivilwork

Q2 What data do you needto providefor an accurate proposal?
A Criticaldata includeslag sampleanalysis(chemicalcomposition hardnessabrasiveness) requiredhourlyannual tonnage incomingfeed sizemaximum lump size desiredfinalproductsizesand any siterestrictions

Q3 How does this solutionimpact our ongoing operational manning?
A The plantsaredesignedfor semiautomaticoperationfromacontrolroom Typically oneoperatorcan manage thecrushing circuit reducing directlabor comparedto multiplemobileunits Howevermaintenanceplanningrequirements remain

Q4 Whatisthetypical deliveryandlead timefrom orderto commissioning?
A For standardizedplants lead timesrangebetween26and36weeks dependingon component sourcing Custom designsrequire additional engineeringtime Lead timeis definedafter finalprocess designcriteriaare approved

P5 ¿Se ofrecen garantías de desempeño??
A Yes contractsinclude guaranteedcapacity basedon agreed feedmaterial specifications as wellas guaranteed maximum power consumption Product sizing guaranteescan alsobe providedforspecific configurations

Q6 How are spare parts managed longterm?
A We maintaindetailed billofmaterialsforall fabricatedplants Criticalspare partkits arerecommendedat purchase Comprehensive drawingsandsupplychain informationare providedtothe client ensuringpartstraceabilityfor decades

Q7 Can the plant handle variationsinslag composition between differentfurnacesor campaigns?
A The robustdesignaccommodatesnormalvariability Featureslike hydraulic adjustmentallowoperatorsto compensate For majorschangesin materialcharacteristics(eg switchingfromBFtoEAFslag)a processreviewis recommended