1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Managing slag is a persistent operational bottleneck with tangible costs. Êtes-vous confronté à ces défis?
Coûts d'élimination élevés & Responsabilité: Les frais de mise en décharge des scories non traitées augmentent, and improper storage creates environmental liability.
Manutention inefficace des matériaux: Surdimensionné, irregular slag chunks cause feeder blockages, conveyor damage, and significant downtime for manual breaking or equipment clearing.
Flux de revenus perdus: Un contenu métallique précieux reste piégé dans les scories, and inconsistent particle size limits profitable resale as aggregate or industrial feedstock.
Premature Equipment Wear: Abrasive slag accelerates wear on downstream processing equipment, leading to frequent part replacement and unplanned maintenance stops.
Contraintes spatiales & Risques pour la sécurité: Accumulating stockpiles consume valuable plant space, while unstable piles and dust generation pose safety risks.

La question centrale est: comment transformer ce sous-produit problématique d'un centre de coûts en un centre contrôlé, processus de génération de revenus? The answer lies in a purposeengineered China slag crusher plant.

2. APERÇU DU PRODUIT

A China slag crusher plant is a stationary or semimobile crushing circuit specifically configured for the size reduction and liberation of materials like blast furnace slag, voler un coup, and nonferrous smelter slag. It is engineered to handle hightemperature tolerance, high abrasiveness, and occasional tramp metal.

Flux de travail opérationnel:
1. Primary Crushing/Jaw Crushing: Alimentation en scories de grande taille (jusqu'à 1 mois et plus) est réduit à une taille gérable (environ. 150250mm) using a robust jaw crusher or hydraulic impact hammer.
2. Séparation magnétique (Étape critique): A suspended selfcleaning magnet or magnetic drum over a conveyor removes liberated ferrous metals for recovery and sale.
3. Concassage secondaire/tertiaire: Cone crushers or impact crushers further reduce the material to the target product size (par ex., 040mm), ensuring complete liberation of remaining metallics.
4. Dépistage & Tri: Vibrating screens classify the crushed material into specified fractions for different market applications (par ex., base de route, additif pour ciment).
5. Récupération finale des métaux: A secondstage magnetic separator captures any remaining fine ferrous content.

Champ d'application & Limites:
Portée: Idéal pour les aciéries intégrées, fonderies, metal smelting plants, and dedicated slag processing yards. Effective on aircooled blast furnace (petit ami) slag and basic oxygen furnace (BOF) voler un coup.
Limites: Not suitable for processing molten slag without specialized cooling systems. Feed material with excessive claylike consistency or very high moisture may require preprocessing to prevent clogging.

3. CARACTÉRISTIQUES PRINCIPALES

Concasseur à mâchoires robuste | Base technique: High manganese steel jaws & reinforced frame design | Avantage opérationnel: Sustained throughput of large, hard slab slag with minimal deformation; handles occasional uncrushables via hydraulic toggle adjustment | Impact sur le retour sur investissement: Réduction des temps d'arrêt de l'étage primaire jusqu'à 30% versus standard crushers in abrasive service

Système de séparation magnétique intégré | Base technique: Multistage arrangement of permanent and electro magnets across main conveyors | Avantage opérationnel: Continu, automated recovery of ferrous scrap directly within the crushing circuit without separate handling | Impact sur le retour sur investissement: Direct revenue generation from recovered metal; protects downstream crushers from damage

Système de revêtement résistant à l'abrasion | Base technique: Replaceable liners made from AR400/500 steel or ceramic composites in highwear zones | Avantage opérationnel: Extends service intervals for hoppers, chutes, and crusher cavities exposed to constant abrasive flow | Impact sur le retour sur investissement: Réduit le coût par tonne des pièces d'usure d'en moyenne 25% et réduit les heures de travail de maintenance

Graissage centralisé & Système hydraulique | Base technique: Automated lubrication points for bearings and centralized hydraulic power unit for adjustments | Avantage opérationnel: Ensures critical components are lubricated under all conditions; allows safe remote adjustment of crusher settings for product size changes | Impact sur le retour sur investissement: Increases bearing service life by up to 40%, éviter des pannes coûteuses

Vibration Damping Foundations | Base technique: Engineered base frame with antivibration pads or custom concrete foundation plans provided | Avantage opérationnel: Minimizes transmitted vibration to surrounding structures; ensures stable operation of sensitive screening equipment | Impact sur le retour sur investissement: Reduces longterm structural maintenance costs and improves screening accuracy for better product quality

Contrôle basé sur un API & Panneau de surveillance | Base technique: Programmable Logic Controller with touchscreen HMI displaying amperage, température, et les paramètres de production | Avantage opérationnel: Operators can monitor plant health from a central location; automated sequences prevent incorrect startup order which can cause blockages | Impact sur le retour sur investissement: Enables oneperson operation; diagnostic data reduces meantimetorepair by an estimated 20%

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | This Slag Crusher Plant Solution | Avantage (% amélioration) |
|||||
| Taux de récupération métallique | ~8590% | >96% | +611% rendement accru |
| Durée de vie des pièces d'usure (Primaire) | 80,000 120,000 tonnes | 150,000 200,000 tonnes | +60% extended service |
| Consommation d'énergie spécifique | Varies widely Optimized motorcrusher matching & efficient drive design Up to 15% kWh/tonne inférieur |
| Average Availability ~85% >92% +7% more uptime |
| Dust Emission Control Basic bag filters Multistage cyclone + bag filter system Exceeds local environmental standards |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de traitement: Configurable à partir de 50 TPH à plus 400 TPH.
Taille d'alimentation maximale: Up to 1000mm x 1200mm slab material.
Gamme de tailles du produit final: Adjustable between 05mm to 040mm.
Exigences d'alimentation: Total installed power from 200kW to 800kW+ depending on configuration; standard supply at 380V/50Hz/3Phase (autres tensions disponibles).
Spécifications des matériaux clés:
Cadre principal & Trémie: Q345B Carbon Steel
HighWear Liners & Plaques à mâchoires：Mn18Cr2 / AR450 Steel
Bande transporteuse：EP400/3 with high abrasionresistant covers
Dimensions physiques (Configuration typique): Length ~4070m x Width ~1525m x Height ~1218m.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust emission concentration <20mg/Nm³.

6. SCÉNARIOS D'APPLICATION

Integrated Steel Mill Slag Yard Challenge:

Problème spécifique:
A major mill faced rising landfill costs for steel slag stockpiles exceeding ten years. The hardened slabs contained recoverable metal but were too dense for older equipment.

Solution:
Implementation of a turnkey China slag crusher plant featuring a primary hydraulic jaw crusher for slab breaking and two stages of magnetic separation.

Résultats:
Résultats quantifiables:
The plant processes over 250 TPH of legacy stockpile material. Ferrous metal recovery generates over $1.2M USD annually in additional revenue. The consistent aggregate produced is sold to local road construction projects.

Copper Smelter Slag Processing Challenge:

Problème spécifique:
A smelter needed to liberate entrapped copper granules from granulated slag before disposal. Existing hammer mills created excessive fines (10mm) that were difficult to separate via gravity methods.

Solution:
Installation of a specialized China slag crusher plant using a multicavity impact crusher configured for controlled shattering rather than pulverizing.

Résultats:
Résultats quantifiables:
Liberation efficiency improved by over X%. The resulting coarse granule concentrate achieved higher purity (>90%), significantly improving smelter return rates while reducing tailings volume by X%.

7. CONSIDÉRATIONS COMMERCIALES

Equipment pricing tiers are structured around capacity and automation level:

1. Niveau standard (100150 TPH): Includes core crushing circuit with basic magnetic separation and manual controls.
2.Niveau de performances (200300 TPH): Adds secondary crushing stage，Automatisation des automates，enhanced dust suppression，and comprehensive wear monitoring sensors.
3.Niveau Premium (300+ TPH): Fully automated system with remote monitoring capability，advanced metal detection，and spare parts package.

Fonctionnalités facultatives：
• Mobile primary crushing module on tracks
• Additional nonferrous metal sorting（eddy current separator）
• Complete soundproofing enclosures
• Preengineered steel structure building

Forfaits de services：
• Mise en service & Operator Training（Standard）
• Annual Preventive Maintenance Contract（Recommended）
• Full Wear Parts Supply Agreement（for predictable costperton）

Options de financement：
Direct purchase，modalités de location，and project financing solutions are available through partnered institutions，often tailored based on projected ROI from metal recovery.

8.FAQ

Q：Can your China slag crusher plant integrate with our existing conveyors和screening system？
UN：Oui。Engineering drawings can be provided early in the process。Our plants are designed as modular systems。Inlet和outlet points，as well as control signals，can be interfaced with your current infrastructure。

Q：What is the expected operational impact on our maintenance team？
UN：Your team will require training on new PLC controls和specialized wear part更换 procedures。The centralized lubrication和modular liner design aim to simplify routine tasks。Field data shows maintenance hours per ton processed typically decrease after the initial learning period。

Q：How do you ensure consistent quality across different production batches？
UN：We employ standardized design platforms和source key components（bearings，moteurs，crusher castings）from certified Tier1 suppliers。Every plant undergoes fullload factory acceptance testing（FAT）with customerwitnessed performance verification before shipment。

Q：What commercial terms are standard？
UN：Standard terms are FOB Chinese port或CIF destination port。Payment commonly involves an advance payment against proforma invoice，a payment against shipping documents，and retention upon successful commissioning。

Q：What does implementation typically involve on our site？
UN：It requires prepared foundations（plans supplied），adequate utility connections（power，water），and crane access。Our scope includes supervision of mechanical erection，electrical connection指导,et mise en service。Total onsite time varies from X到Y weeks depending on scale。

Q：How is tramp metal（e.g., bucket teeth）handled？
UN：The primary jaw crushers in our configuration include hydraulic overload protection that allows uncrushable objects to pass without catastrophic failure。These are then removed manually at the first magnetic separation point。

Q：What kind of output particle shape can be expected？
UN：Using our recommended secondary cone crusher configuration produces more cubical product ideal for aggregate markets。An impact crusher secondary stage yields a slightly more fractured shape suitable as railway ballast。This choice depends on your target product specification