1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Managing bulk slag is a persistent bottleneck with tangible costs. Êtes-vous confronté à ces défis opérationnels?
Coûts d'élimination élevés & Lost Revenue: Landfilling slag represents a direct financial loss and increasing disposal fees. Valuable metallic content is wasted, and potential revenue from processed aggregate is unrealized.
Inefficient Primary Size Reduction: Surdimensionné, irregular slag chunks from ladles or pits cause frequent bridging in feeders, leading to unplanned downtime for manual clearing and damaging downstream equipment.
Usure excessive & Coûts d'entretien: La nature abrasive des scories dégrade rapidement les composants standard du concasseur., resulting in high parts replacement costs, labor for changes, and production stoppages.
Produit final incohérent: Without controlled crushing, output size varies widely. This leads to poor performance in secondary processing or makes the aggregate unsuitable for consistent sale as a construction material.
Espace & Limites de débit: Stationary crushing circuits may be geographically fixed and costly, while inadequate mobile solutions lack the throughput and durability for continuous bulk slag processing.

La question centrale pour les directeurs d'usine est la suivante: how can you transform a costly waste stream into a controlled, profitable product line while achieving reliable, hightonnage throughput?

2. APERÇU DU PRODUIT

The solution is a purposeengineered Bulk Slag Crusher Plant. This is a heavyduty, semimobile or skidmounted primary crushing system designed specifically for the initial reduction of large, abrasive metallurgical slag.

Flux de travail opérationnel:
1. Alimentation & Présélection: Bulk slag is loaded via excavator or loader into a robust vibrating grizzly feeder, which bypasses subsize material and evenly feeds oversized chunks to the crusher.
2. Concassage primaire: A highinertia jaw crusher or impactor applies massive force to break down large slabs (souvent jusqu'à 1,5 m) into manageable fragments (typically 200mm to 250mm).
3. Décharge & Convoyage: Crushed material is discharged onto a heavyduty belt conveyor system for transport to the next stage—stockpiling, concassage secondaire, or magnetic separation.

Champ d'application: Idéal pour les aciéries, fonderies, and metal recycling yards processing blast furnace (petit ami) scories, four à oxygène basique (BOF) scories, four à arc électrique (AEP) scories, and ladle slag.
Limite clé: This plant is designed for primary reduction. For specific graded aggregates (par ex., 20mm), a secondary crushing and screening circuit will be required downstream.

3. CARACTÉRISTIQUES PRINCIPALES

Mangeoire vibrante robuste pour grizzlis | Base technique: Highstress amplitude drive system | Avantage opérationnel: Eliminates bridging of sticky or oversized slab slag; protects crusher from direct loader impact | Impact sur le retour sur investissement: Reduces feederrelated downtime by an estimated 6080% versus standard apron feeders

AbrasionResistant Crusher Design | Base technique: Manganese steel jaws/liners with optimized nip angle; reinforced rotor assemblies | Avantage opérationnel: Extends wear life in highly abrasive slag environment; maintains consistent gap setting | Impact sur le retour sur investissement: Réduit le coût par tonne des pièces d'usure de 3050% compared to standard quarry crushers

Piège métallique intégré & By-pass | Base technique: Permanent overbelt magnet or pneumatic tramp metal release system | Avantage opérationnel: Removes uncrushable metallic “tramp” (par ex., dents de godet, barres d'armature) before it enters the crushing chamber | Impact sur le retour sur investissement: Prévient les dommages catastrophiques; eliminates associated repair costs and extended downtime

Contrôle basé sur un API & Système de surveillance | Base technique: Centralized control panel with amp draw monitoring, capteurs de température de roulement | Avantage opérationnel: Allows operators to optimize feed rate; fournit une alerte précoce en cas de problèmes mécaniques | Impact sur le retour sur investissement: Permet la planification de maintenance prédictive; improves overall plant availability by optimizing crusher load

Conception modulaire montée sur patins | Base technique: Preassembled structural steel skid with integrated walkways and maintenance platforms | Avantage opérationnel: Significantly reduces onsite installation time and civil works cost; facilitates relocation within site | Impact sur le retour sur investissement: Mise en service plus rapide (semaines contre. mois); improves capital flexibility

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Generic Mobile Plant) | Solution d'usine de concassage de scories en vrac | Avantage (% amélioration) |
| : | : | : | : |
| Durée de vie des pièces d'usure en service de scories | 3045 days for jaw liners | 75100 days for specialized liners | +110% à +120% |
| Disponibilité (Temps de disponibilité) | ~80%, frequent stops for clearing/breakdowns| ~92%, designed for continuous duty| +15% temps de fonctionnement |
| Cohérence du débit| Fluctuates with feed bridging/abrasion| Stable output due to feeder design & power reserve| +25% more predictable tons/hr |
| Événements de dommages causés au métal par des clochards| Several per year requiring major repair| Nearzero with integrated protection systems| ~100% reduction in related incidents |

5. SPÉCIFICATIONS TECHNIQUES

Capacité / Notation: 400 – 1,200 tonnes par heure (TPH), depending on feed size and required product.
Exigences d'alimentation: Puissance totale installée généralement 300 – 600 kW. Configured for 400V/50Hz or 480V/60Hz industrial supply.
Spécifications matérielles: Fabriqué à partir d'acier de construction S355JR; wear surfaces use HARDOX® or equivalent; revêtements de concasseur en acier au manganèse de première qualité (1822% Mn).
Ouverture d'alimentation / Capacité: Primary crusher accepts feed sizes up to 1500mm x 1200mm.
Dimensions physiques (Typique): Skid length: 18m; Largeur: 4m; Hauteur (to top of feeder): 6m. Approximate weight: 90 – 160 tonnes.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C. Les systèmes de pulvérisation de suppression de poussière sont standard.

6. SCÉNARIOS D'APPLICATION

Aciérie intégrée – Traitement des scories de haut fourneau

Défi: A mill faced escalating landfill costs for BF slag and needed to recover metallics while producing a saleable aggregate. Their existing system suffered from low throughput and constant jamming.
Solution: Implementation of a highcapacity Bulk Slag Crusher Plant with an overbelt magnet installed after the primary crusher.
Résultats: Landfill volume reduced by over 85%. Recovered metallics returned to the furnace process stream produced significant annual savings. The consistent 250mm crushed aggregate became a new revenue source.

Four à arc électrique MiniMill

Défi: Processing EAF slag was causing extreme wear on a generalpurpose jaw crusher, requiring liner changes every month at high cost and production loss.
Solution: Installation of a dedicated Bulk Slag Crusher Plant engineered with abrasionresistant alloys and optimized geometry specifically for EAF slag characteristics.
Résultats: Wear part life extended to over three months per set. Maintenance labor hours dedicated to the primary crushing stage were reduced by approximately 65%, réduisant directement les coûts d’exploitation.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification:
Configuration de base (Skidmounted Jaw Crusher Plant): For operations prioritizing robustness over ultimate fines production.
Configuration améliorée (Skidmounted Impact Crusher Plant): For applications where a slightly higher proportion of fines in the primary product is acceptable or desired.
Full Circuit Configuration (Primaire + Secondary Modules): For turnkey production of specific aggregate sizes directly at the source.

Fonctionnalités facultatives / Mises à niveau: Hydraulic adjustment systems for CSS changeovers, advanced dust suppression/filtration modules,
hotslag handling kits,
systèmes de convoyeurs étendus,
and dualpower capability (diesel/électrique).

Forfaits de services: Available tiers include Basic Warranty,
Extended Wear Part Guarantees,
Contrats d'inspection annuelle,
and Comprehensive OnSite Maintenance Agreements with guaranteed response times.

Options de financement: L’équipement peut être acquis par achat direct,
operational lease structures tailored to project cash flow,
or through longterm rentaltoown agreements.

8.FAQ

1.Q:Quelles sont mes exigences en matière de fondation?
UN:The skidmounted design distributes load but requires a level compacted base—typically packed gravel or lean concrete—minimizing extensive civil works compared to stationary plants.

2.Q:What about dust control?
A.The plant includes standard spray nozzle systems at transfer points.For indoor installations or strict environmental regulations,a baghouse filtration module can be added as an option.

3.Q:What ongoing maintenance should we expect?
A.Daily greasing checks,vibrating equipment inspections,and regular monitoring of wear liners.Field data shows planned liner changes are the primary maintenance activity,scheduled based on processed tonnage rather than time.

4.Q:What happens if uncrushable material enters?
A.The integrated tramp metal protection system(overbelt magnet or release system)is designed as the first defense.For extreme events,the hydraulic toggle adjustment on jaw models(or impactor curtain systems)allows relief without causing catastrophic failure.

5.Q:What lead time can we expect from order?
A.Pour les configurations standard,the lead time typically ranges between16to24weeks.This includes engineering,fabrication,factory assembly,and testing prior to shipment