1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

La gestion des scories est un goulot d'étranglement persistant avec des coûts tangibles. Êtes-vous confronté à ces défis opérationnels?
Temps d'arrêt élevés pour les concasseurs primaires: Abrasive slag causes premature wear on jaw plates and mantles, leading to frequent maintenance stops that halt your entire processing line.
Manutention inefficace des matériaux: Surdimensionné, irregular slag chunks from cooling beds jam feeders and conveyors, creating manual intervention points and safety hazards.
Génération d'amendes incontrôlées: Using the wrong crushing technology can produce excessive, lowvalue fines instead of the optimally sized aggregate your customers demand.
Coût total de possession élevé: The combined expense of premature part replacement, temps d'arrêt imprévu, and energyinefficient processing directly erodes profit margins from your slag byproduct.

La question centrale est: how do you reduce this operational friction and transform slag from a disposal headache into a consistent revenue stream? The answer lies in selecting equipment engineered specifically for the task.

2. APERÇU DU PRODUIT

Le [Nom du fabricant] Slag Crusher Plant is a heavyduty, stationary or semimobile processing system designed for the primary and secondary reduction of aircooled blast furnace (petit ami) slag or steel slag. It is not intended for molten slag or materials with high metal content without prior separation.

The operational workflow is engineered for continuity:
1. Alimentation & Présélection: Slag is fed via apron feeder to a scalping screen, removing fine fractions to bypass the crusher and reduce wear.
2. Concassage primaire: Oversize material is directed to a robust impact crusher or jaw crusher, selected for high reduction ratio and ability to handle occasional tramp metal.
3. Transfert de matériel & Concassage secondaire: Crushed material is conveyed to a secondary cone or impact crusher for precise final sizing.
4. Projection finale & Stockage: Material is classified on vibrating screens into commercial aggregate fractions (par ex., 05mm, 510mm, 1020mm) et acheminé vers des stocks désignés.

3. CARACTÉRISTIQUES PRINCIPALES

Système de réglage hydraulique | Base technique: Remotecontrolled hydraulic cylinders replace mechanical shims. | Avantage opérationnel: Your operators can adjust the crusher gap setting in minutes versus hours, enabling quick response to product size requirements or clearing blockages. | Impact sur le retour sur investissement: Réduit les temps d'arrêt pour les ajustements jusqu'à 90%, augmentation de la disponibilité des plantes.

Reinforced Rotor & Pièces d'usure | Base technique: Highchrome martensitic steel castings with ceramic wear tiles in critical areas. | Avantage opérationnel: Withstands extreme abrasion from slag, extending service life before replacement is required. | Impact sur le retour sur investissement: Les données de terrain montrent un 4060% improvement in wear part life compared to standard manganese steel, réduire le coût par tonne concassée.

Piège métallique intégré & Release | Base technique: Permanent magnet overband separator coupled with an automatic release system. | Avantage opérationnel: Continuously removes tramp metal from the crushing circuit, protecting downstream machinery from damage. | Impact sur le retour sur investissement: Prevents costly damage to crusher internals and conveyor belts, éviter les arrêts imprévus.

Graissage centralisé & Surveillance | Base technique: Automated lubrication system with flow sensors connected to plant control panel. | Avantage opérationnel: Garantit que les roulements critiques reçoivent une lubrification appropriée sans intervention manuelle, providing early warning of potential failures. | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements jusqu'à 30% and prevents catastrophic bearing seizures that cause extended downtime.

Conception modulaire montée sur patins | Base technique: Preassembled crusher, mangeoire, and screen modules on structural steel skids. | Avantage opérationnel: Significantly reduces civil works and installation time on your site; facilite un déménagement futur si nécessaire. | Impact sur le retour sur investissement: Réduit les coûts d’installation d’environ 25% and allows revenue generation from crushed material weeks sooner.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Notre solution pour une usine de broyage de scories | Avantage (% amélioration) |
| : | : | : | : |
| Durée de vie des pièces d'usure (Étape primaire) | Manganese Steel Jaws/Blows Bars | HighChrome Alloy with Composite Liners | +50% |
| Disponibilité moyenne (Exécution planifiée) | 8590% (due to adjustment/maintenance)| >94% (via hydraulic adjustment & surveillance) | +59% Augmentation absolue |
| Consommation d'énergie par tonne traitée| Fixedspeed direct drives with low load efficiency| PLCcontrolled VFD drives matching power to load demand| 15% à 20% |
| Installation & Temps de mise en service| 46 weeks for foundation & assemblée| 1014 days for skid interconnection & alignement| 60% |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de traitement: Configurable à partir de 50 TPH à plus 400 TPH of aircooled BF slag.
Options du concasseur primaire: Heavyduty impact crusher (up to 1200mm feed size) or deeptoggle jaw crusher.
Exigence de puissance: La puissance totale installée varie de 150 kW à 600 kW selon configuration.
Spécifications des matériaux clés: Revêtements Hardox® dans les trémies et les goulottes; ST52 structural steel for frames; SEW or Nord gearboxes; SKF/FAG bearings.
Dimensions physiques (Configuration typique): Longueur: ~35m; Largeur: ~12m; Hauteur: ~9 min (varies per model).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; système de suppression de poussière prêt; noise encapsulation available.

6. SCÉNARIOS D'APPLICATION

Integrated Steel Plant – Slag Aggregate Production

Défi: A major steel producer needed to process 250 TPH of blast furnace slag but faced weekly downtime due to wear part changes and conveyor damage from uncaptured metal.
Solution: Implementation of a turnkey slag crusher plant featuring a primary impactor with hydraulic adjustment, an overband magnet at the head pulley, and modular skid design.
Résultats: Wear part cycles extended from 6 semaines à 10 semaines. Metal removal exceeded 95%, eliminating related damage. The plant achieved an average availability of 95%, producing over 600,000 tons of certified construction aggregate annually.

Independent Slag Processing Contractor – Multiple Site Operations

Défi: A contractor servicing multiple mills required a portable solution that could be relocated every 1824 months with minimal reinstallation cost and delay.
Solution: A semimobile slag crushing plant built on tripleaxle trailer modules with quickdisconnect electrical and hydraulic connections.
Résultats: Relocation time between sites reduced from one month to under two weeks. The consistent plant performance allowed standardized maintenance schedules across all client sites, improving operational predictability.

7. CONSIDÉRATIONS COMMERCIALES

Les niveaux de tarification des équipements sont structurés autour de la capacité de débit et du niveau d'automatisation.:
Configuration de base (50150 TPH): Comprend une étape de concassage primaire, dépistage de base, manual adjustment systems.
Configuration optimisée (150300 TPH): Comprend le primaire & secondary crushing stages automated metal separation PLC control system
HighCapacity Configuration (300+ TPH): Full circuit with tertiary crushing advanced dust suppression automated lubrication remote monitoring capability

Optional features include noise enclosures hot material handling packages specific wear protection alloys advanced particle shape optimization systems

Service packages are offered as annual maintenance contracts providing scheduled inspections guaranteed parts availability priority technical support Financing options include standard capital purchase finance lease agreements or tollprocessing partnerships where we operate the plant on your site

8. FAQ

1\. Is this plant suitable for processing stainless steel slag?
Our standard configuration is optimized for carbon steel BF/BOF slags For highly abrasive stainless steel slags we recommend specific metallurgy for wear parts which we provide as an option following material testing

2\. What are the expected operating costs per ton?
Based on historical data operating costs including power wear parts labor routine maintenance typically range between $0 $1 $2 per ton processed depending on local energy rates abrasiveness index of your specific slag

3\. Comment ce système s'intègre-t-il à notre équipement de manutention existant?
The plant is designed as a standalone node It includes feed hopper discharge conveyors can be interfaced with your existing belt systems via standardized chutework electrical connections We conduct pre installation interface reviews

4\. What training do you provide for our operations maintenance teams?
We provide comprehensive onsite training covering normal operation troubleshooting safety procedures routine maintenance tasks Documentation includes detailed operation manuals parts lists schematic diagrams

5\. What warranty period do you offer what does it cover?
We offer a standard months warranty on machinery workmanship defects extended warranties are available Critical components like crusher shafts main bearings carry specific warranty terms outlined in our commercial proposal