1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Gérer les scories de votre acier, ferroalliage, or nonferrous metal production is a persistent operational bottleneck. Inefficient processing directly impacts your bottom line through high handling costs, lost revenue from unrecovered metallics, and unplanned maintenance downtime. Êtes-vous confronté à ces défis?
Coûts d'élimination élevés & Responsabilité: Transporting and landfilling untreated slag consumes significant budget and creates longterm environmental liability.
Unrecovered Metal Loss: Ineffective crushing leaves valuable metallics locked in slag, representing direct revenue loss per ton processed.
Temps d'arrêt excessif & Porter: Standard crushers not built for abrasive slag suffer rapid wear part failure, causing frequent, costly production stops.
Sortie incohérente & Bottlenecks: An undersized or illconfigured crusher creates irregular feed size for downstream screening and sorting, limiting overall plant throughput.
Space & Logistics Constraints: Bulky, multistage crushing setups require excessive floor space and complicate material flow within a confined plant layout.

La question centrale pour les directeurs d'usine est la suivante: how can you transform slag from a cost center into a recoverable asset while ensuring relentless, lowmaintenance operation?

2. APERÇU DU PRODUIT

Our Commercial Slag Crusher Plant is a heavyduty, stationary processing system engineered specifically for the continuous reduction of aircooled or granulated metallurgical slag. It is designed to liberate encapsulated metal for maximum recovery and produce a consistently sized aggregate product for commercial sale.

Flux de travail opérationnel:
1. Alimentation & Présélection: Runofplant slag is fed via loader or conveyor into an integrated grizzly or scalping screen to remove fine fractions and bypass noncrushable debris.
2. Réduction de la taille primaire: Oversize material is directed into the core impactor or jaw crusher module, applying high inertia to fracture slabs and liberate metallic inclusions.
3. Séparation des métaux & Décharge: Crushed material discharges onto a heavyduty discharge conveyor, typically passing over an overhead magnetic separator to extract liberated ferrous metal.
4. Concassage secondaire (Facultatif): For specific aggregate specifications, a secondary cone crusher module can be incorporated for precise cubical shaping.

Champ d'application: Designed for integrated steel plants, fonderies, fonderies de cuivre, and ferroalloy producers processing blast furnace (petit ami) scories, four à oxygène basique (BOF) scories, electric arc furnace (AEP) scories, and nonferrous slags.

Principales limites: Not designed for primary rock mining applications or processing unsorted demolition debris with excessive tramp metal. Feed size must comply with crusher opening specifications.

3. CARACTÉRISTIQUES PRINCIPALES

HeavyDuty Rotor & Impact System | Base technique: Highinertia rotor with monolithic manganese hammers/bimetal blow bars | Avantage opérationnel: Sustains high impact energy against abrasive slag with minimal wear rate; handles occasional tramp metal without catastrophic failure | Impact sur le retour sur investissement: Reduces wear part change frequency by up to 40%, lowering direct parts cost and labor hours dedicated to maintenance.

Réglage hydraulique & Clairière | Base technique: Integrated hydraulic cylinders for apron positioning and crusher housing opening | Avantage opérationnel: Allows operators to adjust product gradation in minutes and clear blockages safely without manual entry into the crushing chamber | Impact sur le retour sur investissement: Eliminates hours of dangerous manual labor per blockage event; enables quick optimization for varying feed materials.

AbrasionResistant Lining System | Base technique: Bolton wear liners made of AR400/500 steel in highwear zones | Avantage opérationnel: Protects the crusher’s structural frame from abrasion, preserving its longterm integrity and preventing costly structural repairs | Impact sur le retour sur investissement: Extends the service life of the main chassis by years, protéger votre investissement en capital.

Mangeoire à grizzlis intégrée | Base technique: Steppededge vibrating grizzly feeder with adjustable spacing | Avantage opérationnel: Removes subsize material before crushing (increasing effective capacity) and evenly distributes feed across full rotor width for uniform wear | Impact sur le retour sur investissement: Increases total plant throughput by preventing chokefeeding of fines; extends wear part life through even distribution.

Contrôle basé sur un API & Surveillance | Base technique: Centralized control panel with PLC featuring amp draw monitoring, bearing temperature sensors, and vibration detection points | Avantage opérationnel: Provides realtime operational data to prevent overload conditions; enables predictive maintenance scheduling based on actual load data | Impact sur le retour sur investissement: Prevents major component failures; allows maintenance planning during scheduled stops.

Modular Base Frame Design | Base technique: Preassembled crusher module mounted on a unified heavyduty support frame | Avantage opérationnel: Simplifies foundation requirements and reduces onsite assembly time during installation; allows for future reconfiguration or relocation | Impact sur le retour sur investissement: Réduit les coûts d’installation d’environ 25% and minimizes plant commissioning downtime.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Solution standard de l'industrie | Our Commercial Slag Crusher Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Durée de vie des pièces d'usure (Blow Bars/Hammers) | Manganese Steel Castings | Proprietary BiMetal Alloy Castings / Ceramic Composite Liners Optional| +3550% durée de vie plus longue |
| Metal Liberation Efficiency (Ferrous Recovery) ~90% liberation rate postcrush >95% liberation rate postcrush +57% increase in recovered metal yield |
| Throughput Consistency Under Abrasive Feed ~15% capacity drop over 100 heures d'ouverture <8% capacity drop over 100 heures d'ouverture +47% more stable output |
| Unplanned Downtime Due to Blockages Average 812 hours per month Average 50% reduction in blockagerelated stops |
| Coût total de possession (5Year Estimate) Based on parts + travail + downtime Based on our field data analysis Estimated 2030% inférieur |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 à plus 600 tonnes métriques par heure (TPH), depending on feed size and desired product specification.
Exigences d'alimentation: Primary drive motors from 150 kW à 450 kW; total plant power dependent on configuration (mangeoires, convoyeurs).
Feed Size Maximum: Up to 1000mm x 1200mm slab handling capability (dépendant du modèle).
Gamme de tailles de produits: Adjustable from 150mm down to 40mm in primary configuration; finer sizes achievable with secondary circuit.
Spécifications des matériaux clés: Mainframe fabrications from heavyduty steel plate; Rotor shaft forged alloy steel; Bearings rated for high shock loads; Wear components in premium manganese or chromium iron alloys.
Dimensions physiques (Typical Primary Module): Approximately L12m x W4m x H5m. Foundation loads provided per project.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust suppression system connections standard.

6. SCÉNARIOS D'APPLICATION

Integrated Steel Plant – BOF Slag Processing

Challenge A major steel producer faced escalating landfill costs for BOF slag and needed to recover contained scrap metal more efficiently. Their existing jaw crusher suffered constant liner wear and poor metal liberation.
Solution Implementation of a highinertia impactortype Commercial Slag Crusher Plant with an integrated magnetic head pulley on the discharge conveyor.
Results Metal recovery increased by 6%. The consistent 80mm output improved downstream screening efficiency by 15%. Wear part costs decreased by an estimated $18,000 annually due to longer service intervals.

Ferrochrome Smelter – Lump Slag Aggregate Production

Challenge A smelter required a reliable method to process large lumps of aircooled ferrochrome slag into a saleable construction aggregate. Throughput was limited by frequent jamming in their old compressionstyle crusher.
Solution Installation of a grizzlyfed impact crusher plant with hydraulic adjustment and clearing capabilities specifically configured for highly abrasive ferrochrome slag.
Results The plant achieved a steady throughput of 180 TPH without blockages. The hydraulic system enabled quick product size adjustments between rail ballast and road base specifications. Aggregate sales now offset over onethird of the site’s raw material handling costs.

7. CONSIDÉRATIONS COMMERCIALES

Our Commercial Slag Crusher Plants are offered in three primary tiers:
1. Standard Duty Plant: Pour un tonnage inférieur (<150 TPH) or intermittent use applications processing less abrasive slags like some nonferrous varieties.
2. HeavyDuty Plant: Our most common configuration for continuous operation in EAF/BOF steel mills at midrange capacities (150400 TPH), featuring standard abrasion packages.
3. UltraDuty Plant: Engineered for maximum abrasion resistance (>400 TPH) in severe applications like stainless steel or highly abrasive alloy slags, featuring premium wear materials throughout.

Optional features include secondary/tertiary crushing modules automated metal sorting systems advanced dust suppression packages extended remote monitoring service contracts

Financing options are available including capital lease operating lease project financing terms tailored to match your cash flow requirements

8.FAQ

Q What are my foundation requirements?
A We provide detailed foundation drawings specific to your ordered model Our modular base frame design simplifies civil work but requires a solid reinforced concrete pad designed by your contractor based on our load data

Q How does this integrate with my existing conveyors screens?
A Our engineering team will review your current layout feed points discharge heights The crusher plant is designed with standard conveyor interfaces We can specify necessary chutes transfer points as part of the scope

Q What is the expected operational availability?
A When maintained according to our schedule field data shows operational availability exceeding92 excluding planned maintenance stops This is due primarilyto the robust designand predictive monitoring systems

Q Can you provide performance guarantees?
A Yes we offer guaranteed minimum throughput capacity based on agreed feed material specificationsand product size as well as maximum power consumption under load These are detailed in commercial proposals

Q What does the typical service package include?
A Our recommended package includes scheduled inspections remote monitoring support annual bearing grease analysisand guaranteed priority shipmentof criticalwear parts This structured approach maximizes uptime

Q How long does installation take?
A Fora standard heavy dutyplantwith preassembled modules onsite mechanical erection typically requires1014 dayswith an experienced crew Electrical connectionand commissioning add further time dependenton site readiness