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 & Falta del tiempo: Inconsistent feed size and tramp metal cause frequent jams in standard crushers, halting your entire material recovery line and delaying downstream processing.
Desgaste excesivo & Costos de mantenimiento: The highly abrasive nature of slag rapidly degrades standard manganese steel components, leading to unscheduled shutdowns and high spare part expenditures.
Inefficient Liberation of Valuables: Inadequate crushing fails to fully liberate metallic fractions (ferrosos y no ferrosos) from the slag matrix, leaving recoverable value in your waste stream and reducing overall plant revenue.
Polvo & Environmental Control Issues: Dry crushing processes generate significant fugitive dust, creating environmental compliance risks and unsafe working conditions for personnel.

If these issues are impacting your profitability, the central question is: ¿Cómo se logra la coherencia?, highvolume slag reduction with lower operational costs and maximized metal recovery? La respuesta está en un diseño específico planta trituradora de escoria.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

A planta trituradora de escoria is a stationary or semimobile processing system specifically engineered for the primary, secundario, and sometimes tertiary crushing of metallurgical slag (alto horno, horno de acero, cobre, etc.). Its design prioritizes durability against abrasion and impact while ensuring efficient liberation of entrapped metals.

Flujo de trabajo operativo:
1. Alimentar & Pre-selección: Runofpile slag is fed via loader or conveyor into a vibrating grizzly feeder, que elimina fracciones finas (30milímetros) para evitar la trituradora primaria, increasing system efficiency.
2. Trituración Primaria: Oversize material is reduced by a heavyduty jaw crusher or impactor designed for high compressive strength feed.
3. Separación de metales & Trituración Secundaria: The crushed product typically passes over an overhead magnetic separator to remove liberated ferrous scrap. The remaining material is further reduced by a cone crusher or secondary impactor to achieve the target grain size (p.ej., 20milímetros).
4. Apresto & Almacenamiento: A final vibrating screen classifies the product, con material de gran tamaño recirculado. Onspec material is conveyed to stockpile for sale as aggregate or for further processing.

Ámbito de aplicación: Ideal para plantas siderúrgicas integradas, fundiciones, patios de procesamiento de escoria, and aggregate producers handling ferrous and nonferrous slags.

Limitaciones: Not designed for primary mining of virgin rock or for processing materials with extreme moisture or clay content without preconditioning.

3. CARACTERÍSTICAS PRINCIPALES

Alimentador Grizzly Vibrante de Servicio Pesado | Base técnica: Highstrength eccentric shaft drive | Beneficio operativo: Removes fines upfront, regulates feed to the primary crusher preventing chokefeeding | Impacto del retorno de la inversión: Reduces primary crusher load by up to 30%, lowering wear and energy consumption per ton processed.

AbrasionResistant Liner Packages | Base técnica: Airhardening manganese steel or composite ceramic/metal alloys | Beneficio operativo: Vida del revestimiento extendida por 4060% compared to standard manganese in highabrasion zones | Impacto del retorno de la inversión: Decreases downtime for liner changes and reduces annual spare parts inventory cost.

Circuito de separación magnética integrado | Base técnica: Overband selfcleaning magnets positioned at optimal discharge points | Beneficio operativo: Continuously extracts liberated ferrous metal during crushing stages | Impacto del retorno de la inversión: Creates a direct revenue stream from scrap recovery and protects downstream conveyors and crushers from metal damage.

Engrase centralizado & Sistemas hidráulicos | Base técnica: Automated lubrication points for bearings and hydraulic adjustment/tramp release systems | Beneficio operativo: Ensures critical components are lubricated under all operating conditions; allows quick clearing of uncrushables | Impacto del retorno de la inversión: Previene fallas catastróficas en los rodamientos (a major cause of downtime) and minimizes manual maintenance intervention time.

Integración del sistema de supresión de polvo | Base técnica: Conjuntos de boquillas en puntos de transferencia conectados al suministro de agua con control de solenoide | Beneficio operativo: Effectively controls dust emissions at source during crushing operations | Impacto del retorno de la inversión: Mitiga los riesgos de incumplimiento ambiental y reduce los costos laborales de limpieza..

Robust Structural Fabrication | Base técnica: Stiffened frame design with heavyduty crawler or fixed plant support legs | Beneficio operativo: Maintains alignment under continuous highvibration loads over years of operation | Impacto del retorno de la inversión: Eliminates costly structural repairs and prevents premature failure of mounted components due to frame flexing.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Solución estándar de la industria | Nuestra solución de planta trituradora de escoria | Ventaja (% mejora) |
| : | : | : | : |
| Disponibilidad / tiempo de actividad | 8085%, frequent jamming from tramp metal >8592%, hydraulic tramp release clears uncrushables in 8% aumentar |
| Vida útil del revestimiento en etapa primaria (acero manganeso) ~40,000 MT throughput ~60,000 MT throughput >50% mejora |
| Specific Power Consumption ~0.8 1.0 kWh/ton ~0.65 0.75 kWh/tonelada >20% reducción |
| Metal Recovery Efficiency Manual picking postcrushing Inprocess magnetic separation at 2 stages Scrap recovery yield increased by 1525% |
| Dust Emission at Transfer Points Dry crushing with local extraction Wet suppression system at source PM10 emissions reduced by >90% |

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 50 TPH por encima 300 Escoria procesada TPH.
Requisitos de energía: La potencia total instalada normalmente oscila entre 150 kilovatios (para 50 Planta TPH) a 450 kilovatios (para 300 Planta TPH), dependiente de la configuración.
Especificaciones de materiales: Primary crusher jaws/liners manufactured from premiumgrade Manganese Steel (1822%). Critical wear plates utilize AR400 steel. Structural frames fabricated from heavyduty ISMC/ISMB sections.
Dimensiones físicas (Típico 150 Planta TPH): Longitud (~25m) x Ancho (~8m) xAltura (~7 millones). Available in fixed skidmounted or semimobile trailer versions.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +50°C. Dust suppression system requires clean water supply at 3040 PSI; consumption approx. 50 liters per ton crushed.

6. ESCENARIOS DE APLICACIÓN

Integrated Steel Plant Slag Yard Challenge:

A major steel producer faced inconsistent feed from aged stockpiles causing daily chokeups in their existing crusher, limiting aggregate production to just one shift per day due to maintenance needs.

Solución:

Implantación llave en mano planta trituradora de escoria featuring an extradeep crushing chamber jaw crusher with hydraulic toggle adjustment for quick CSS changes, paired with a powerful overhead magnet on the primary discharge belt.

Resultados:

Plant availability increased to three full shifts. Aggregate production rose by 210%. Recovered ferrous scrap generated sufficient revenue to cover the plant’s operating labor costs annually.

Copper Smelter Tailings Reprocessing Challenge:

A smelter sought to recover residual copper from old dump slag but found that conventional hammer mills created excessive fines (3milímetros), rendering gravity separation ineffective.

Solución:

A twostage planta trituradora de escoria using a jaw crusher followed by a cone crusher in closed circuit with a screen was deployed for controlled size reduction targeting 12mm+3mm.

Resultados:

The optimized grain size distribution improved recovery rates in the downstream jig plant by over 18%. The robust design handled the highly abrasive silicarich slag with liner life meeting projected targets.

7. CONSIDERACIONES COMERCIALES

Niveles de precios: Solutions are projectspecific but generally fall into three categories:
Standard SkidMounted Plant (50100 TPH): A costeffective entry point for lower volume processors.
Modular MediumCapacity Plant (100200 TPH): The most common configuration offering optimal balance of output and investment.
HighCapacity Fixed Stationary Plant (200300+ TPH): Designed for largescale producers requiring maximum uptime and automation.
Características opcionales: Vibrating feeder vs apron feeder; secondary cone vs impact crusher; automated metal detection system; advanced PLC control panels with remote monitoring capability; sound enclosures.
Paquetes de servicios: Planes de garantía extendida; contratos de inspección anual; guaranteed spare parts delivery schedules (p.ej., 48hour critical parts availability).
Opciones de financiación: Estructuras de arrendamiento de equipos a través de instituciones financieras asociadas.; milestonebased project payment plans for turnkey installations.

8. Preguntas frecuentes

1. Is your Slag Crusher Plant compatible with our existing conveyors and material handling infrastructure?
Our engineering team can design transfer heights and discharge points to match your current layout during the project specification phase.

2. ¿Cuál es el nivel de ruido operativo esperado??
With standard equipment enclosures, Las mediciones de campo generalmente muestran niveles por debajo 85 dB(A) at a distance of one meter from the machinery when processing dry slag.

3. ¿Cuánto tiempo lleva la instalación??
For a skidmounted plant delivered preassembled on our frames, onsite commissioning can be completed within two weeks after foundation readiness upon arrival at your site

4.¿Pueden proporcionar garantías de rendimiento??
Yes we offer guaranteed minimum throughput capacity based on defined feed material characteristics as well as maximum power consumption per ton

5.¿Cuáles son las condiciones de pago típicas??
For custom plants terms are generally structured as follows
30% advance payment
60% against dispatch
10% after successful commissioning

6.Do you offer training for our operators
Comprehensive training covering operation routine maintenance safety procedures troubleshooting is provided onsite during commissioning

7.How do you handle warranty claims
We maintain regional service hubs Warranty claims initiate through our service manager who coordinates diagnostics part dispatch if needed technician deployment if required