1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Managing slag stockpiles presents persistent operational and financial challenges. Are you contending with inefficient manual breaking methods that bottleneck your material flow? Does inconsistent feed size from primary crushing reduce your downstream screening and separation efficiency, leading to valuable metal loss? Are you facing excessive wear on crusher components from abrasive slag, driving up maintenance costs and unplanned downtime? The costs of slow processing, high consumable expenses, and metal recovery inefficiency directly impact your site’s profitability. How can you transform this byproduct into a consistent, highvalue aggregate stream while controlling operational expenditure? The solution requires a purposeengineered system designed for the specific demands of slag reduction.

2. APERÇU DU PRODUIT

UN Usine de concassage de scories is a stationary or semimobile processing system engineered specifically for the size reduction of aircooled blast furnace (petit ami) slag or steel slag. Its core function is to crush large slag lumps into precisely graded aggregates for use in construction, construction de routes, or as a feedstock for further metal recovery processes.

Flux de travail opérationnel:
1. Alimentation & Présélection: Slag is loaded via excavator or loader into a robust feed hopper, often with a grizzly section to bypass fine material.
2. Concassage primaire: A heavyduty jaw crusher or impact breaker reduces large lumps (often up to 1m+) à une taille gérable.
3. Transfert & Concassage secondaire: Le matériau est transporté vers un concasseur secondaire (typically a cone crusher or impact crusher) for further refinement to the target product size.
4. Dimensionnement & Séparation: Crushed material passes through vibrating screens to separate it into specified fractions (par ex., 05mm, 510mm, 1020mm). Magnetic separators are often integrated at this stage to extract remaining ferrous metal.
5. Stockage: Les granulats classés sont transportés vers des stocks désignés pour expédition.

Champ d'application: Idéal pour les aciéries intégrées, chantiers de traitement de scories autonomes, et producteurs de granulats spécialisés dans les sous-produits industriels.
Limites: Non conçu pour les scories fondues; feed material must be aircooled and solid. Performance is contingent on proper feed size control and the specific abrasiveness and composition of the source slag.

3. CARACTÉRISTIQUES PRINCIPALES

Configuration du concasseur robuste | Base technique: Manganese steel jaws/liners with optimized crushing chamber geometry | Avantage opérationnel: Sustained high throughput of highly abrasive material with reduced risk of premature failure | Impact sur le retour sur investissement: Lower costperton crushed via extended wear life and reduced frequency of liner changes.
Système intégré de récupération des métaux | Base technique: Overband magnetic separators positioned at key discharge points | Avantage opérationnel: Continu, automated extraction of residual ferrous metal from the aggregate stream | Impact sur le retour sur investissement: Creates an additional revenue stream from recovered scrap metal while protecting downstream equipment from tramp metal damage.
Vibration Dampening Base Frame | Base technique: Reinforced steel frame with antivibration mounts for major components | Avantage opérationnel: Minimizes structural stress and transmitted vibration, ensuring stable operation and reducing foundation requirements | Impact sur le retour sur investissement: Lowers installation complexity and cost, enhances longterm structural integrity of the plant.
Graissage centralisé & Points de surveillance | Base technique: Manifolded lubrication lines for all major bearing points | Avantage opérationnel: Permet de sécuriser, efficient routine maintenance without requiring access to multiple isolated points during operation | Impact sur le retour sur investissement: Reduces lubrication time by up to 50%, promotes bearing health, and decreases unscheduled downtime.
Adjustable Discharge Setting System | Base technique: Hydraulic or mechanical adjustment on secondary/tertiary crushers | Avantage opérationnel: Allows operators to quickly change final product sizing to meet different market specifications | Impact sur le retour sur investissement: Enables rapid response to changing customer demands, maximizing plant utilization and sales opportunities.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Industry Standard Slag Processing | Notre solution pour une usine de broyage de scories | Avantage (% Amélioration) |
| : | : | : | : |
| Débit de tonnage (Matériau abrasif)| Variable, often declines with liner wear| Consistent output maintained via optimized wear part design & couler| Jusqu'à 1520% more consistent yield over liner life |
| Efficacité de récupération des métaux| Singlestage magnetic separation, often manual cleaning| Multistage magnetic separation at optimal transfer points| Ferrous recovery rates improved by 2530% |
| Temps d'arrêt pour maintenance (Programmé)| Dispersed lube points; manual setting adjustment| Centralized systems & hydraulic adjustment features| Routine service time reduced by approximately 40% |
| Cohérence de la forme du produit| Basic crushing circuits can produce flaky aggregates| Chamber optimization & crushing stage matching produces more cubical product| Improved cubicity index enhances aggregate value for premium applications |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 TPH à plus 300 TPH, depending on feed size and required product grading.
Exigences d'alimentation: La puissance totale installée varie généralement de 150 kW à 600 kW, supplied by mains connection or onboard diesel generator set for semimobile units.
Spécifications matérielles: Primary wear components (doublures, impeller bars) manufactured from highchrome martensitic steel or premium manganese steel. Structural frames use heavyduty rolled steel sections.
Dimensions physiques (Configuration typique): Footprint varies by capacity; un 150 TPH plant may require approximately 25m (L) x 18m (W) x 12m (H).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C. Dust suppression systems are standard to maintain environmental compliance.

6. SCÉNARIOS D'APPLICATION

Parc à scories d'aciérie intégré | Défi: Inefficient primary breaking causing backlog; low recovery of valuable metallics from old slag dumps leading to lost revenue. | Solution: Deployment of a turnkey Slag Crusher Plant with highcapacity jaw crusher for primary reduction and two stages of magnetic separation. | Résultats: Processing rate increased to 180 TPH; recovered an average of 8 tons of ferrous metal per operating day; cleared legacy stockpile within projected timeline.

Commercial Aggregate Producer Specializing in Industrial Byproducts | Défi: Existing plant struggled with extreme abrasiveness of steel slag, resulting in unsustainably high wear part costs and poor product shape limiting marketability.| Solution: Installation of a purposebuilt Slag Crusher Plant featuring specialized abrasionresistant liners and a cone crusher secondary stage for improved particle shape.| Résultats: Durée de vie des pièces d'usure prolongée de plus de 60%; produced highquality cubical aggregate meeting road base specifications; opened access to highervalue construction contracts.

7. CONSIDÉRATIONS COMMERCIALES

Nos usines de concassage de scories sont proposées en trois niveaux principaux:
Configuration standard: A robust base plant covering primary crushing, basic screening/conveying, and singlestage magnetic separation.
Configuration de récupération améliorée: Adds secondary crushing for finer grading optimization and multistage magnetic separation drums/scanners.
Fully Modular/Mobile Configuration: Skidmounted or trailerbased units offering shorter installation times and relocation flexibility.

Optional features include automated dust suppression systems, advanced vibration monitoring sensors, ensembles de production d'énergie embarqués, and custom conveyor lengths.

We provide comprehensive service packages ranging from annual inspection plans to fullturnkey operation & contrats d'entretien. Financing options including leasing structures are available through our partners to facilitate capital expenditure planning.

8. FAQ

1. Is your Slag Crusher Plant compatible with our existing conveyors and screening equipment?
Oui; our engineering team designs the transfer heights and discharge points based on your site layout survey data provided during quotation.

2. What is the expected operational impact on our power consumption?
Field data shows that an optimized plant design uses energy more efficiently per ton processed than piecemeal systems due to reduced recirculation loads.

3. How does pricing typically scale with capacity?
Pricing follows an economyofscale curve but is also influenced by specific requirements like level of metallurgical recovery needed or environmental enclosures.

4. What are the standard commercial terms offered?
We typically offer FOB pricing exworks alongside CIF quotations for international buyers; payment terms are structured around project milestones such as FAT (Test d'acceptation en usine).

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