1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

La gestion des scories est un goulot d’étranglement critique mais coûteux. Êtes-vous confronté à ces défis opérationnels persistants?
Temps d'arrêt imprévus: Frequent breakdowns of underengineered crushers halt your entire processing line, coûtant des milliers de dollars par heure en perte de débit et de main d'œuvre.
Usure excessive & Coûts d'entretien: La nature abrasive des scories dégrade rapidement les composants standard du concasseur., leading to unsustainable spending on replacement parts and maintenance labor.
Gradation du produit incohérente: Poor crushing yields unevenly sized material, compromising the quality and market value of your final aggregate product.
Coûts opérationnels élevés: Inefficient power consumption and low throughput per ton directly erode your profit margins on every processing cycle.
Conformité & Risques pour la sécurité: Equipment not built for heavyduty mineral processing can pose safety hazards and fail to meet stringent site or environmental regulations.

What if your slag processing plant could achieve predictable output, coût inférieur, and operate with greater reliability? The solution requires equipment engineered specifically for this demanding task.

2. APERÇU DU PRODUIT

The ISO Certified Slag Crusher Plant is a stationary or semimobile crushing circuit designed explicitly for the primary, secondaire, and tertiary reduction of iron, acier, et scories de ferro-alliage. Engineered by a private label manufacturer with deep expertise in mineral processing, it transforms bulky slag feed into valuable, specificationgrade aggregate.

Flux de travail opérationnel:
1. Concassage primaire: Alimentation en scories de grande taille (jusqu'à 1000mm) is reduced by a robust jaw crusher or impactor.
2. Présélection & Concassage secondaire: Material is screened; oversize is routed to a cone crusher for further reduction.
3. Projection finale & Stockage: Crushed material is classified into precise product fractions (par ex., 05mm, 520mm) via vibrating screens and conveyed to stockpiles.

Champ d'application: Idéal pour les aciéries intégrées, chantiers de traitement de scories autonomes, and aggregate producers handling blast furnace (BFS) ou laitier de fourneau d'acier.

Limites: Not designed for virgin rock mining/quarrying primary applications or for processing materials with high moisture content without preprocessing.

3. CARACTÉRISTIQUES PRINCIPALES

Rotor robuste & Conception de la chambre | Base technique: Analyse par éléments finis (FEA) répartition optimisée des contraintes | Avantage opérationnel: Withstands continuous impact from dense, abrasive slag with minimal deformation | Impact sur le retour sur investissement: Extends major component service life by up to 40%, reducing capital replacement cycles

Liner & Wear Part Metallurgy | Base technique: Highchrome white iron alloys and manganese steel formulations | Avantage opérationnel: Provides exceptional resistance to abrasive wear specific to slag composition | Impact sur le retour sur investissement: Réduit le coût par tonne des pièces d'usure d'en moyenne 30% compared to standard crushers

Conduite intelligente & Power Management | Base technique: Hydrostatic or direct drive systems with PLCcontrolled variable frequency drives (VFD) | Avantage opérationnel: Optimizes power draw based on load, prevents jamming, and allows soft starts | Impact sur le retour sur investissement: Reduces energy consumption by 1525% and eliminates downstream damage from stall events

Integrated Tramp Metal Protection | Base technique: Hydraulic or pneumatic release systems coupled with reinforced construction | Avantage opérationnel: Automatically discharges uncrushable metals that commonly exist within slag feed | Impact sur le retour sur investissement: Prevents catastrophic damage to crusher internals, avoiding repair costs exceeding tens of thousands per incident

Configuration d'usine modulaire | Base technique: Bolttogether skid or module design with standardized interfaces | Avantage opérationnel: Enables rapid site installation, reconfiguration, or future plant expansion with minimal civil work | Impact sur le retour sur investissement: Cuts installation time and costs by up to 50% compared to welded foundationbased plants

Graissage centralisé & Système de surveillance | Base technique: Automated lubrication system with flow sensors and centralized control point | Avantage opérationnel: Ensures critical bearings receive correct lubrication without manual intervention in highdust environments | Impact sur le retour sur investissement: Eliminates bearing failure due to undergreasing, a leading cause of unplanned downtime

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Typical Crusher) | Solution d'usine de broyage de scories certifiée ISO | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité / Temps de disponibilité | 8085% (high downtime for wear changes) |> 92% (scheduled maintenance only) |> 8% Amélioration |
| Durée de vie des pièces d'usure (Doublures)| Based on granite/limestone; severely reduced in slag| Alloyspecified for slag abrasion| Jusqu'à 40% Durée de vie plus longue |
| Consommation d'énergie par tonne| Variateurs à vitesse fixe; inefficient under partial load| VFDoptimized load management| 1525% Réduction |
| Finished Product Cubicity| Variable; often flaky due to improper compression| Cohérent, cubical aggregate from optimized cavity| Improved yield in premium grades |
| Installation / Temps de mise en service| 46 semaines pour installation à fondation fixe| 1015 days for modular skid plant| ~60% Faster Deployment |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 TPH à plus 400 TPH final product.
Taille de l'alimentation: Accepts runofslag up to 1000mm edge length.
Exigences d'alimentation: Plantwide requirement from 150 kW à 600 kW selon configuration; supplied at either standard industrial voltages.
Spécifications des matériaux clés:
Crusher Main Frame: Fabricated from heavyduty steel plate (min. limite d'élasticité >355 MPa).
Porter des doublures / Plaques à mâchoires / Concaves / Barres de soufflage: Premiumgrade manganese steel (Mn18Cr2/Mn22Cr2) or High Chrome Iron (Cr26/28).
Plateformes d'écran / Conveyor Skirting : Abrasionresistant steel liners.
Dimensions physiques (Example MidRange Plant): Environ. Longueur: 25m x Largeur: 8m x Hauteur: 6m
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dustsealed electrical components; IP65 rating on critical motors and controls.

6. SCÉNARIOS D'APPLICATION

Recyclage intégré du parc à scories des aciéries

Challenge A major steel producer faced escalating landfill costs for BFS slag and needed consistent aggregate quality for internal road construction but suffered from high crusher maintenance costs.
Solution Implementation of a turnkey ISO Certified Slag Crusher Plant configured as a twostage closed circuit system tailored specifically for their BFS chemistry.
Results Achieved consistent production of 20mm aggregate at >95 TPH availability. Reduced external aggregate purchase by $180k annually while cutting internal wear part costs by an estimated $50k/year versus their previous setup.

Independent Aggregate Producer Processing EAF Slag

Challenge An aggregate contractor securing Electric Arc Furnace (AEP) slag contracts experienced poor product yield due to uncrushable tramp metal causing weekly breakdowns in their generalpurpose cone crusher.
Solution A primary jaw crusher plant equipped with enhanced tramp metal release was installed as the dedicated first stage ahead of their existing circuit.
Results Tramp metal incidents causing downtime were reduced by over . The jaw's robust design increased primary throughput by , allowing the overall plant to meet new contract volumes reliably.

7. CONSIDÉRATIONS COMMERCIALES

Our private label manufacturing model provides flexibility across commercial needs:

Niveaux de tarification: Solutions range from core equipment supply only up through full turnkey project delivery including civil works supervision.
Fonctionnalités facultatives & Mises à niveau: Consider magnetic separation modules integrated into conveyors , systèmes de suppression de poussière , systèmes d'échantillonnage automatisés , or extended remote monitoring packages .
Forfaits de services: Choose from basic commissioning support up through comprehensive annual maintenance contracts including guaranteed spare parts availability .
Options de financement: We work with established partners offering equipment leasing structures .

8. FAQ

1. Q Is this ISO Certified Slag Crusher Plant compatible with our existing conveyors screens?
A Yes provided interface specifications are shared during design Our standard designs use common industry transfer heights belt widths We provide detailed interface drawings .

2 Q What is the expected operational impact during installation?
A For modular skid plants site impact is minimal requiring only leveling cranes Electrical connection typically causes the longest lead time We provide detailed site preparation guidelines .

3 Q How does the private label model benefit us as a buyer?
A It removes brand premiums associated with major OEMs while delivering equivalent performance You invest directly in engineered specifications not marketing overhead This typically results in cost savings .

4 Q What are typical payment terms?
A Standard commercial terms involve progress payments tied key milestones such as order confirmation completion fabrication ready shipment successful commissioning These are detailed proposal .

5 Q Can you guarantee specific wear part life metrics?
A We provide databacked performance projections based your specific analysis However final wear life depends actual material characteristics feed rate We guarantee metallurgical specification parts supplied meet exceed stated standards .

6 Q What training do you provide our operators maintenance staff?
A Comprehensive training conducted during commissioning covers safe operation routine maintenance troubleshooting procedures All documentation including manuals parts lists provided digital hard copy formats .

7 Q Who handles aftersales service technical support?
A Direct access our engineering support team via dedicated channels We maintain critical spare parts inventory ensure rapid response times support requests .