Slag Crusher Plant Processing Plant Shipping
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??
Bajo rendimiento & Alto tiempo de inactividad: Inefficient primary crushing and frequent clogging from uncrushable material halt your entire processing line, Costando miles por hora en producción y mano de obra perdidas..
Desgaste excesivo & Costos de mantenimiento: Standard crushers rapidly deteriorate when processing highly abrasive slag, leading to premature failure of liners, martillos, and rotors. The resulting parts replacement and unplanned maintenance erode your profit margins.
Tamaño del producto final inconsistente: Poorly controlled crushing results in uneven aggregate size distribution, reducing the market value of your slag product and limiting its application in highspecification construction or cement blending.
Alta complejidad operativa & Risk: Reliance on multiple, nonintegrated units for feeding, aplastante, cribado, and metal recovery increases manpower needs, peligros de seguridad, and points of potential failure.
Is your current setup delivering the reliable throughput and product quality required for profitability? La solución reside en un diseño específico slag crusher plant processing plant.
2. DESCRIPCIÓN GENERAL DEL PRODUCTO
A slag crusher plant processing plant is a stationary or semimobile integrated system designed specifically for the reduction, cribado, and separation of metallurgical slag (alto horno, horno de acero). Se transforma en grande, irregular slag feed into precisely graded aggregates for sale or further use.
Flujo de trabajo operativo:
1. Primary Receiving & Pre-selección: Runofpile slag is fed via loader into a robust hopper with a grizzly section to bypass fine material.
2. Primario & Secondary Size Reduction: A heavyduty jaw crusher performs initial breaking. A secondary impactor or cone crusher then reduces the material to the target size range.
3. Cribado de materiales & Clasificación: Las cribas vibratorias separan el material triturado en fracciones de producto específicas (p.ej., 05milímetros, 510milímetros, 1020milímetros).
4. Recuperación de metales (Opcional): Overband magnets or magnetic head pulleys extract remaining ferrous metal from the crushed stream for recycling revenue.
5. Almacenamiento & Dispatch: Graded aggregates are conveyed to designated stockpiles for loadout.
Ámbito de aplicación: Procesamiento de escoria de alto horno (BFS), robar golpe (accidente cerebrovascular LD), escoria de ferroaleaciones, y otros agregados minerales no metálicos.
Limitación clave: Not designed for primary rock mining or processing extremely hard virgin rock; optimal performance requires feed material within specified hardness (escala de mohs) and size parameters.
3. CARACTERÍSTICAS PRINCIPALES
HeavyDuty Reciprocating Plate Feeder | Base técnica: Controlled volumetric flow with adjustable stroke | Beneficio operativo: Ensures even, chokefree material delivery to the primary crusher, preventing surges and overloads | Impacto del retorno de la inversión: Eliminates crusher stalls; increases overall plant throughput by up to 25% versus vibratory feeders in sticky slag conditions.
Manganese Steel Crusher Liners | Base técnica: Workhardening austenitic manganese steel construction | Beneficio operativo: Liners gain hardness upon impact, dramatically extending service life under severe abrasion | Impacto del retorno de la inversión: Reduce la frecuencia de reemplazo del revestimiento en 4060%, lowering parts inventory costs and maintenance downtime.
Integrated Metal Separation System | Base técnica: Permanent overband magnet with selfcleaning belt | Beneficio operativo: Automatically recovers residual tramp metal during processing | Impacto del retorno de la inversión: Generates ancillary revenue from scrap metal; protects downstream crushers from damage; improves final product purity.
Sistema de control PLC centralizado | Base técnica: Controlador lógico programable con interfaz hombre-máquina (HMI) panel | Beneficio operativo: Allows singleoperator monitoring and control of entire plant flow from a protected cabin | Impacto del retorno de la inversión: Reduces labor requirements; enables quick troubleshooting; provides production data for efficiency analysis.
Diseño modular montado sobre patines | Base técnica: Preassembled structural steel skids for major components | Beneficio operativo: Significantly reduces onsite civil work and installation time | Impacto del retorno de la inversión: Cuts installation costs by approximately 30% and allows for potential relocation or plant expansion.
HeavyDuty Vibrating Screens with Deck Guards | Base técnica: HighG force exciters and easily replaceable deck panels | Beneficio operativo: Provides consistent sizing efficiency even with damp or fine slag materials; guards contain fly rock | Impacto del retorno de la inversión: Ensures onspec product yield exceeding 95%, maximizing sales value; mejora la seguridad del operador.
4. VENTAJAS COMPETITIVAS
| Métrica de rendimiento | Estándar de la industria (Basic Crushing Circuit) | Nuestra solución de planta trituradora de escoria | Ventaja (% Mejora) |
| : | : | : | : |
| System Uptime| ~7580% (frequent stops for clearing,jams) |>92% (engineered flow control) |>15% Mejora |
| Vida útil del revestimiento en la trituradora primaria| 6090 días (manganeso estándar) |>180 días (premium/workhardening) |>100% Mejora |
| Tons Processed per ManHour| Lower due to multipoint operation |>25% higher (centralized control) |>25% Mejora |
| Tasa de recuperación de metales| Manual picking or basic magnet |>99% ferrous recovery (optimized placement) |>30% Improvement in purity/revenue |
| Instalación & Tiempo de puesta en servicio| 812 semanas (field assembly) |>57 semanas (modular skid design) |>~40% Reduction |
5. ESPECIFICACIONES TÉCNICAS
Capacidad de procesamiento: Configurable desde 50 a más 300 toneladas por hora (TPH).
Requisitos de energía: Total connected load typically ranges from 150 kW a 450 kW depending on plant configuration; supplied at 415V/50Hz or customized.
Especificaciones de materiales: Fabricado con acero estructural S355JR; critical wear components in AR400 abrasionresistant steel and Grade I manganese steel.
Opciones de trituradora primaria: Jaw Crusher sizes from 750x500mm up to 1200x1000mm feed opening.
Opciones de trituradora secundaria: trituradora de impacto (for less abrasive BFS) up to Ø1400mm rotor diameter, or Cone Crusher (for highly abrasive steel slag).
Screen Specifications: Single or doubledeck vibrating screens from 1800x4800mm up to 2400x6000mm.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C; dust suppression spray systems are standard.
6. ESCENARIOS DE APLICACIÓN
Integrated Steel Plant – Slag Processing Yard Challenge:
A major steel producer was landfilling LD converter slag due to an inefficient old crushing circuit that produced inconsistent aggregate sizes and suffered constant hammer wear in the impactor.
Solución:
Implementation of a turnkey slag crusher plant processing plant featuring a deepchamber jaw crusher for primary reduction followed by a robust cone crusher for secondary crushing. A twostage screening system was integrated with powerful overband magnets.
Resultados:
The plant achieved a consistent product yield of over 200 TPH of highvalue aggregate sold to the local cement industry. Metal recovery increased revenue by an additional $50k annually. Planned maintenance intervals extended from monthly to quarterly.
Independent Aggregate Producer – Diversification
Desafío:
A traditional quarry operator sought to diversify into industrial byproduct processing but needed a system capable of handling highly variable feed sizes without constant reconfiguration.
Solución:
A semimobile slag crusher plant on skids with a heavyduty apron feeder was selected alongside an impact crusher with hydraulic adjustment for quick product size changes.
Resultados:
The operator could now process both purchased demolition concrete y sourced steelworks slag using one flexible unit. Changeover between materials takes less than two hours through hydraulic settings adjustments only.
7. CONSIDERACIONES COMERCIALES
Our solutions are offered across three tiers:
1. Planta de configuración estándar ($250k$500k):
Includes core modules—feeder, primary jaw crusher,criba vibratoria,and conveyors—for basic sizing operations.Optional features include magnetic separator,kit de supresión de polvo,and starter motor controls package.Service package includes commissioning plus oneyear parts warranty.
2.
3.Enhanced Recovery Plant ($500k $900k):
Adds secondary cone/impactor crushers,a multideck sizing screen,and automated metal separation systems.Optional features include finished product washing systems,tramp iron protection devices,and advanced PLC automation.Service package extends warranty coverage plus annual preventive maintenance inspections.Financing options available through partner institutions include equipment leasing plans starting at $8k/month.
4.Turnkey Processing Facility ($900k+):
Fully integrated system including receiving hoppers,surge bins,total dust collection enclosure,and automated weighloading out system.Custom engineering available.Optional features include remote monitoring via SCADA systems.Service package includes full operational training,a dedicated service manager,and guaranteed spare parts delivery within agreed terms.Comprehensive project financing can be structured based on client credit profile.
\Financing terms subject to credit approval.Please inquire directly regarding current rates.
Preguntas frecuentes
1.q:What types of raw feed size can your standard plants accept?
A:The standard primary jaw configuration accepts feed lumps up to ~650mm edge length.Larger inlet sizes are available as an option.Precrushing may be advised if runofpile chunks exceed this dimension consistently
2.q:What is the typical lead time between order placement commissioning?
A.For standard configurations lead time is typically between16and24weeks.This covers manufacturing,pruebas de fábrica,and shipment.Modular skid design reduces site installation time significantly compared traditional builtinplace plants
3.q:What ongoing maintenance does this equipment require?
A.Daily visual inspections weekly greasing checks are required.Major planned maintenance involves periodic liner replacements based actual wear rates which we help predict using historical field data.A comprehensive preventive schedule provided
4.Q.How does this integrate with our existing conveyor stockpile system?
A.The plants are designed as complete circuits but can be adapted tie into existing infrastructure.We require details regarding existing conveyor heights capacities ensure proper interface engineering during design phase
5.Q.What kind power supply needed operate typical200TPHplant?
A.A200TPHslag crushing screening circuit typically requires total connected load approximately300kW.We recommend consulting local electrical engineer ensure adequate supply transformer capacity softstart systems minimize grid disturbance
6.Q.Are spare parts readily available long after purchase?
A.All critical wear parts common consumables stocked our central warehouse.We provide recommended initial spare parts list order ensure minimal downtime guarantee availability support throughout equipment lifecycle
7.Q.What aftersales service support included?
A.All installations include commissioning supervision operator training period.We offer tiered service contracts ranging emergency breakdown support scheduled preventive maintenance visits full annual inspection programs