1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Manejo de escoria, a challenging byproduct of metal production, directly impacts your plant’s bottom line and operational continuity. ¿Estás enfrentando estos desafíos persistentes??
Tiempo de inactividad no planificado: Frequent breakdowns of underengineered crushers halt your entire material handling chain, costing thousands per hour in lost processing time and labor.
Desgaste excesivo & Costos de mantenimiento: The highly abrasive nature of slag rapidly degrades standard crushing components, lo que lleva a un gasto insostenible en piezas de repuesto y mano de obra de mantenimiento.
Salida inconsistente & Cuellos de botella: An illmatched crusher produces uneven particle size distribution, causing downstream screening inefficiencies and storage issues, ultimately delaying shipment to your customers.
Altos costos operativos: Inefficient power consumption and the need for secondary or even tertiary crushing stages erode profit margins on what should be a valuable recycled product.

La pregunta central para los gerentes de planta es: how do you transform this abrasive liability into a consistent, profitable stream without compromising reliability? The solution lies in specifying a purposebuilt planta trituradora de escoria.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

A planta trituradora de escoria is a stationary or semimobile system engineered specifically to reduce large chunks of aircooled or granulated metallurgical slag into precisely graded aggregates. Unlike generic rock crushers, it is designed from the ground up to withstand extreme abrasion and intermittent tramp metal.

Flujo de trabajo operativo:
1. Recepción primaria & Alimentación: Slag is delivered via dump truck or loader into a robust hopper, often equipped with a grizzly feeder to bypass subsize material and protect the primary crusher.
2. Reducción de tamaño primario: Una trituradora de mandíbulas de servicio pesado o un rompedor de impacto realiza la trituración inicial., reducing large slabs to manageable diameters (típicamente <200milímetros).
3. Trituración Secundaria & Cribado: El material se transporta a un cono secundario o trituradora de impacto para una mayor reducción.. The crushed output is then screened via vibrating screens to separate product into specified size fractions (p.ej., 05milímetros, 510milímetros, 1020milímetros).
4. Manejo de materiales & Almacenamiento: Onspec aggregate is conveyed to designated stockpiles for loading and transport. Oversize material is recirculated back to the secondary crusher in a closedloop system.

Ámbito de aplicación: Designed for ferrous (alto horno, acero) and nonferrous (cobre, dirigir) slags. Ideal for integrated metal plants and standalone slag processing yards.
Limitaciones: Not suitable for primary ore processing or extremely hard igneous rock. Feed size must be controlled per plant design specifications.

3. CARACTERÍSTICAS PRINCIPALES

Revestimientos resistentes a la abrasión de servicio pesado | Base técnica: Highchrome white iron or manganese steel castings | Beneficio operativo: La vida útil del revestimiento aumentó en 60100% en comparación con materiales estándar, drastically reducing changeout frequency | Impacto del retorno de la inversión: Lowers costperton for wear parts and reduces maintenance downtime by up to 30% anualmente.

Sistema de protección de metales vagabundos | Base técnica: Hydraulic or pneumatic release mechanisms on crushers; metal detectors on feed conveyors | Beneficio operativo: Prevents catastrophic damage from uncrushable metals mixed within slag | Impacto del retorno de la inversión: Eliminates risk of major rotor or shaft damage, protecting a capital asset worth hundreds of thousands.

PLCBased Automated Control Panel | Base técnica: Centralized programmable logic controller with load management and fault diagnostics | Beneficio operativo: Permite el control de un solo operador, optimiza el consumo de energía, and provides clear alarm indicators for rapid troubleshooting | Impacto del retorno de la inversión: Reduces labor requirements and minimizes unplanned stops through predictive alerts.

Diseño modular montado sobre patines | Base técnica: Patines de acero estructural preensamblados para componentes principales. | Beneficio operativo: Significantly reduces civil works and onsite installation time by up to 40% | Impacto del retorno de la inversión: Faster commissioning gets your revenuegenerating operation online sooner with lower initial construction costs.

Alimentador Grizzly Vibrante de Servicio Pesado | Base técnica: Robust feeder with adjustable grizzly bars for prescreening | Beneficio operativo: Removes fines prior to primary crushing, increasing throughput efficiency and reducing unnecessary wear on the primary chamber | Impacto del retorno de la inversión: Improves overall plant capacity by 1525% while lowering energy consumption per ton.

Sistema cerrado de supresión de polvo | Base técnica: Strategically placed spray nozzles at transfer points coupled with dust extraction vents | Beneficio operativo: Maintains compliant airborne particulate levels, ensuring a safer working environment and meeting regulatory standards | Impacto del retorno de la inversión: Evita posibles multas y paros laborales por incumplimiento ambiental.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (planta trituradora genérica) | Nuestra solución de planta trituradora de escoria | Ventaja (% mejora) |
|||||
| Desgaste parte de la vida (Primario) | 3045 Días | 6090 Días | +100% |
| Disponibilidad de tiempo de actividad del sistema | 8085% | 9295% | +12% |
| Power Consumption/Ton | Base | Cargas de motor optimizadas & efficient drive design |18% |
| Rendimiento del producto terminado | Variable sizing requiring recrush Consistent grading within spec bands Recrush volume reduced by ~25% |
| Instalación & Puesta en servicio| 812 Semanas 57 Semanas 40% timetooperation |

5. ESPECIFICACIONES TÉCNICAS

Capacidad de procesamiento: Configurable desde 50 TPH por encima 300 TPH.
Tamaño de alimentación máximo: Up to 800mm slab size (dependiente del modelo).
Requisitos de energía: La carga total conectada normalmente oscila entre 150 kW a 450 kilovatios; Diseñado para suministro de voltaje industrial estándar. (400V/50Hz o personalizado).
Especificaciones de la trituradora: Primary jaw crusher sizes from 750x500mm up to 1200x1500mm; Secondary cone crushers with heavyduty mantle/bowl liners.
Especificaciones de materiales: Crusher housings in fabricated steel plate; Liners in Mn18Cr2 / Aleación con alto contenido de cromo; Conveyor belts with high abrasionresistant covers.
Dimensiones físicas (Configuración típica): Huella de aproximadamente 40 m. (l) x 20m (W.). Skid designs minimize foundation needs.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +45°C; dust suppression system rated for effective operation up to 80% humedad relativa.

6. ESCENARIOS DE APLICACIÓN

Reciclaje integrado de patios de escoria de plantas siderúrgicas

Desafío: A major steel producer faced escalating landfill costs for blast furnace slag and needed an onsite solution creating saleable aggregate. Their existing equipment suffered weekly liner failures.
Solution Implementation of a turnkey planta trituradora de escoria featuring primary jaw crushing followed by secondary cone crushing with automated screening.
Results Achieved consistent production of three aggregate grades within six weeks of commissioning. Wear part lifecycle extended from three weeks to seven weeks. The operation converted a cost center into a profit stream within one year.

Contratista independiente de procesamiento de escoria

Challenge A contractor processing slag from multiple sources required high mobility between sites without sacrificing durability or capacity.
Solution A semimobile skidmounted planta trituradora de escoria, where primary and secondary modules could be relocated independently via lowloader trailers.
Results Reduced site setup time from three weeks to five days per location through prewired modules. Se superó la disponibilidad de la planta 93%, allowing the contractor to fulfill multiple longterm supply contracts reliably.

7. CONSIDERACIONES COMERCIALES

Our solutions are offered in clear pricing tiers based on capacity:
Nivel I (200 TPH): Fully customized highvolume systems with advanced automation options.

Optional features include magnetic separators for residual metal recovery automated greasing systems remote monitoring telemetry packages extended dust control enclosures

Service packages range from basic preventive maintenance plans comprehensive annual service contracts including wear part supply financing options are available including leaseto own structures equipment loans tailored support project cash flow

8.Preguntas frecuentes

What types of slag are suitable?
Designed primarily aircooled blast furnace basic oxygen furnace steel slags copper smelter slags Granulated slags may require specific feed arrangements due density

How does handle tramp metal?
Systems incorporate multiple protection layers including hydraulic release mechanisms primary jaw optional metal detectors feed conveyor automatically stop belt uncrushable object detected

¿Cuál es el plazo típico de instalación para la entrega??
For standard configurations lead time manufacturing ranges months Complete delivery installation commissioning typically completed weeks following arrival site

Can integrate existing conveyors screens?
Yes plants engineered modular basis can interface existing downstream equipment provided specifications match Our engineering team will review layout compatibility

What ongoing maintenance requirements?
Daily visual checks lubrication Weekly bolt tightening inspections Scheduled liner replacements based monitored wear rates Predictive maintenance data provided via control system alerts