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??
Tiempo de inactividad no planificado: La obstrucción frecuente y el desgaste abrasivo en las trituradoras estándar provocan paradas de mantenimiento no programadas, detener el procesamiento posterior y costar miles de dólares por hora en producción perdida.
Altos costos operativos: Premature failure of wear parts not only incurs high replacement expenses but also demands significant labor hours for changeouts, directly impacting your maintenance budget.
Rendimiento inconsistente & Calidad del producto: Inadequate crushing force or improper chamber design results in uneven slag reduction, producing oversized material that recirculates, wasting energy and creating an inconsistent product for sale or further processing.
Seguridad & Preocupaciones ambientales: Manual breaking of large slag skulls or handling of uncrushed material increases site risk. Dust generation during inefficient crushing can lead to compliance issues and community complaints.

Is your current solution equipped to handle the extreme abrasiveness and unpredictable feed size of metallurgical slag while maintaining profitability?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO: OEM Slag Crusher Plant

An OEM Slag Crusher Plant is a heavyduty, stationary or semimobile crushing system engineered specifically for the primary and secondary reduction of blast furnace (novio) escoria, escoria de horno de acero, y otros subproductos metalúrgicos. Se transforma en grande, irregular slag feed into a precisely graded aggregate for use in cement production, bases de carreteras, o lastre ferroviario.

Flujo de trabajo operativo:
1. Alimentar & Pre-selección: Runoffurnace slag is fed via loader or conveyor into a heavyduty grizzly or scalping screen to bypass fine material.
2. Trituración Primaria: Oversized material enters a robust primary crusher (típicamente un tipo de mandíbula o impacto) designed for high compression strength and abrasion resistance.
3. Trituración Secundaria & Cribado: Crushed material is conveyed to a secondary cone or impact crusher for further size reduction, then screened to specification.
4. Almacenamiento & Despacho: Correctly sized slag aggregate is conveyed to stockpiles for curing or direct loadout.

Ámbito de aplicación: Diseñado para plantas siderúrgicas integradas, patios de procesamiento de escoria independientes, and metal recycling facilities handling ferrous slags.

Limitaciones: Not suitable for primary crushing of virgin rock in hightonnage mining quarries where feed material characteristics differ significantly from slag.

3. CARACTERÍSTICAS PRINCIPALES

Rotor de servicio pesado & Diseño de cámara | Base técnica: High inertia kinematics and cascading rockonrock impact | Beneficio operativo: Effective reduction of large, slabby slag with minimal wear on metal components | Impacto del retorno de la inversión: Reduces wear part consumption by up to 30% compared to direct impact methods, Reducir el costo por tonelada..

Sistema de revestimiento resistente a la abrasión | Base técnica: Interchangeable liners made from proprietary highchrome white iron alloys | Beneficio operativo: Extends operational intervals between liner changes under continuous abrasive feed | Impacto del retorno de la inversión: Los datos de campo muestran una 4060% Mejora de la vida útil del revestimiento respecto al acero al manganeso estándar., decreasing part costs and labor downtime.

Ajuste hidráulico & Claro | Base técnica: Cilindros hidráulicos integrados para ajustar la separación de la trituradora y liberar metales atrapados. | Beneficio operativo: Allows operators to adjust product size onthefly and clear blockages in minutes without manual intervention | Impacto del retorno de la inversión: Elimina horas de limpieza manual peligrosa; maintains consistent product gradation for optimal sales value.

Automatización basada en PLC & Escucha | Base técnica: Centralized control system with load management and performance tracking | Beneficio operativo: Optimizes crusher performance based on feed conditions; provides realtime alerts for maintenance events | Impacto del retorno de la inversión: Prevents catastrophic damage from overloads; improves overall plant throughput predictability by 1520%.

Marco reforzado & Eje del rotor | Base técnica: Análisis de elementos finitos (FEA) optimized steel structures and forged alloy shafts | Beneficio operativo: Withstands high shock loads from uncrushable contaminants and large feed without structural fatigue | Impacto del retorno de la inversión: Mitigates risk of major structural failure, protegiendo su inversión de capital a largo plazo.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Trituradora genérica) | OEM Slag Crusher Plant Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Vida del revestimiento (Escoria abrasiva)| Manganese Steel Liners (Standard Grade)| Proprietary HighChrome Iron Alloy Liners| +50% Average Life Increase |
| Tiempo de recuperación del metal atrapado| Manual Barring & Disassembly (24 horas)| Hydraulic Clearing System (<10 minutos)| 90% Downtime per Event |
| Disponibilidad (tiempo de actividad)| 8590% (Programado + Paradas no programadas)| 9396% (Predictive Maintenance Enabled)| +58% Annual Production Time |
| Consumo de energía por tonelada| Fixed Speed Drive Systems| LoadAdaptive PLC & VFD Controls| 12% Uso de energía |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 150 a 600+ toneladas por hora (TPH), dependiendo del tamaño del alimento y de la gradación requerida del producto.
Opciones de trituradora primaria: Trituradoras de mandíbulas de servicio pesado (tamaño de alimentación hasta 48") or primary horizontal shaft impactors.
Requisitos de energía: La potencia total instalada de la planta normalmente oscila entre 300 kW a 800 kW según la configuración. Voltage options available for global industrial standards (p.ej., 400V/50Hz, 480V/60Hz).
Especificaciones clave de materiales: Fabricaciones del marco principal de acero S355JR.; rotor shafts from EN24/34CrNiMo6 forged steel; wear liners from ASTM A532 Class III Type A highchrome iron.
Dimensiones físicas (Módulo primario típico): Longitud ~15m, Ancho ~4m, Altura ~5m. Semimobile skid designs available.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C con sistemas de lubricación adecuados. Dust suppression kit compliant with <10 mg/Nm³ emission standards is available.

6. ESCENARIOS DE APLICACIÓN

Planta siderúrgica integrada – Procesamiento de escoria de alto horno

Desafío: A major steel producer faced excessive downtime due to weekly liner changes in their secondary slag crusher and unpredictable blockage events from tramp metal.
Solución: Implementation of a turnkey OEM Slag Crusher Plant featuring the hydraulic adjustment/clearing system and proprietary abrasionresistant liners.
Resultados: Liner change intervals extended from weekly to monthly cycles. Blockage clearance time reduced by over 85%. The plant achieved a quantified increase in annual throughput of approximately 18%, turning a cost center into a profitable aggregate division.

Contratista independiente de procesamiento de escoria

Desafío: A contractor processing purchased slag from multiple sources needed consistent product quality despite highly variable feed composition to meet strict rail ballast specifications.
Solución: Installation of an OEM Slag Crusher Plant with PLCbased automation allowing quick adjustment of crusher parameters based on feed source monitoring.
Resultados: Achieved consistent product gradation with over 95% compliance to specification across all feed sources. This consistency allowed the contractor to secure premium, longterm supply contracts with national rail authorities.

7. CONSIDERACIONES COMERCIALES

Our OEM Slag Crusher Plants are offered in three primary tiers:
1. Configuración básica: Incluye módulo de trituración primaria., basic control panel, and structural steelwork. Ideal for operations with existing secondary screening infrastructure.
2. Configuración mejorada: Adds secondary crushing stage integrated PLC automation suite dust suppression system preinstalled walkways service platforms
3 Turnkey Modular Plant Complete primary secondary tertiary crushing screening circuits enclosed conveyors centralized dust collection advanced predictive monitoring sensors

Optional features include metal detection magnets automated lubrication systems sound attenuation enclosures

Service packages range from annual inspection plans comprehensive multiyear maintenance agreements including parts labor technical support

Financing options include capital purchase operating lease structures payperton agreements tailored support project financing through our network partners

8 Preguntas frecuentes

Q What are the main differences between an OEM Slag Crusher Plant standard aggregate crushing plant
A The core differences lie materials engineering design philosophy An OEM Slag Crusher Plant utilizes higher grade abrasion resistant alloys throughout its wear areas features heavier structures absorb shock loads incorporates specific designs like hydraulic clearing handle uncrushable metals commonly found slag These elements are often optional upgrades standard aggregate plants

Q How does this plant integrate with our existing material handling system
A Our plants are designed modular integration Standard conveyor interface heights belt widths provided early engineering phase We conduct detailed site audits ensure compatibility electrical supply foundations existing workflows Minimal disruption installation key design parameter

P ¿Cuál es el costo operativo esperado por tonelada triturada?
A While site specific industry testing demonstrates typical operational costs including power wear parts scheduled maintenance range $0 $0 per ton processed assuming proper feeding This based achieving rated capacity utilizing recommended service intervals

P ¿Pueden ofrecer garantías de rendimiento?
A Yes we offer guaranteed minimum throughput capacity based agreed feed specifications guaranteed maximum wear part consumption rates expressed grams per ton crushed These are formalized commercial contract

Q What is the typical delivery lead time after order placement
A Lead times vary configuration For standard plant designs lead time typically months For highly customized turnkey solutions detailed engineering may extend this months Firm schedule provided upon project commitment

Q Do you offer operator training onsite commissioning
A Comprehensive operator maintenance training conducted during commissioning phase mandatory part our delivery scope includes both classroom instruction hands equipment training Documentation includes detailed operation manuals parts lists lubrication schedules