1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Managing slag is a persistent, costly bottleneck. Êtes-vous confronté à ces défis opérationnels?
Temps d'arrêt imprévus: Frequent clogging and abrasive wear in standard crushers lead to unscheduled maintenance stops, halting your entire material flow.
Coûts opérationnels élevés: Excessive power consumption from inefficient crushing cycles and the recurring expense of replacing worn manganese steel components directly erode profit margins.
Sortie incohérente: Variable feed size and hardness result in an unpredictable product grade, complicating downstream processing or sales to aggregate markets.
Space & Labor Constraints: Multistage, fragmented crushing setups require significant footprint and constant operator oversight for feeding and monitoring.
Poussière & Noise Compliance: Meeting increasingly stringent site environmental and safety regulations with open or inadequately controlled systems adds complexity and risk.

Is there a slag processing solution engineered to directly address these reliability, coût, and output quality issues?

2. APERÇU DU PRODUIT

The Luxury Slag Crusher Plant is a hightonnage, integrated processing system designed for the primary and secondary reduction of blast furnace (petit ami) scories, voler un coup, et scories de ferro-alliage. It transforms large, irregular slag feed into precisely graded aggregate for cement substitution, base de route, or rail ballast.

Flux de travail opérationnel:
1. Réduction primaire: Matière première (jusqu'à 1000mm) is introduced into a heavyduty jaw crusher or impact crusher for initial size reduction.
2. Présélection & Bypass: A preliminary scalping screen removes fines prior to secondary crushing, increasing overall plant efficiency.
3. Concassage secondaire & Façonner: The core hydraulic cone crusher performs interparticle crushing for optimal cubical product shaping and final size reduction.
4. Dimensionnement final & Séparation: A multideck vibrating screen classifies output into 24 specified product fractions (par ex., 05mm, 510mm, 1020mm).
5. Dust Suppression Integration: A closedloop spray system manages dust at all transfer points, ensuring compliance.

Champ d'application & Limites:
Portée: Ideal for stationary or semimobile plants processing 150 2000 TPH of metallurgical slag. Effective for both ferrous and nonferrous slags with moderate to high abrasiveness.
Limites: Not designed for primary rock mining applications with extremely high compressive strength (>350 MPa). Feed must be prescreened to remove excessive metallic content (clochard métal) to protect crusher internals.

3. CARACTÉRISTIQUES PRINCIPALES

Intelligent Hydraulic CSS Adjustment | Base technique: PLCcontrolled hydraulic setting regulation | Avantage opérationnel: Operators can adjust the crusher's closedside setting (CSS) onthefly for different product grades without stopping the plant. | Impact sur le retour sur investissement: Reduces product changeover time by up to 80%, maximizing utilization and enabling rapid response to market demand.

Liner Wear Compensation System | Base technique: Automated hydraulic positioning that maintains CSS as wear components degrade | Avantage opérationnel: Consistent product gradation is maintained throughout the liner lifecycle without manual intervention. | Impact sur le retour sur investissement: Eliminates periodic yield loss due to drift in CSS, ensuring up to 15% more consistent premiumgrade output.

Hybrid Dust Control System | Base technique: Highpressure micromist nozzles combined with strategic sealing at transfer points | Avantage opérationnel: Effectively suppresses airborne particulate without oversaturating material, which can cause handling issues. | Impact sur le retour sur investissement: Mitigates regulatory noncompliance risks and reduces housekeeping labor by an estimated 30%.

HeavyDuty Rotor & Ensemble de roulement | Base technique: Forged alloy steel rotor with oversized spherical roller bearings in a labyrinth seal arrangement | Avantage opérationnel: Sustains high inertia for efficient crushing of slablike slag pieces with exceptional reliability. | Impact sur le retour sur investissement: Extends major service intervals by 23x compared to standard assemblies, lowering costperton significantly.

Graissage centralisé & Surveillance | Base technique: Automated singlepoint lubricator with feedback sensors connected to the plant SCADA | Avantage opérationnel: Ensures optimal bearing lubrication under all load conditions and provides early warning of potential faults. | Impact sur le retour sur investissement: Empêche les défaillances catastrophiques des roulements, which are a leading cause of extended unplanned downtime.

Modular Discharge Conveyor System | Base technique: Radial slewable stacker or fixed conveyors with variable speed drives | Avantage opérationnel: Enables precise stockpiling of multiple product fractions without requiring additional mobile equipment. | Impact sur le retour sur investissement: Reduces material rehandling costs and minimizes loader fuel consumption and operator hours.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Solution standard de l'industrie | Luxury Slag Crusher Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Durée de vie du revêtement (Abrasive Slag)| Manganese Steel Jaw Liners (~60k tons)| Advanced Composite Jaw/Cone Liners| +4060% Durée de vie prolongée |
| Consommation d'énergie par tonne| Fixed Speed Drives on all motors| Variateurs de fréquence (VFD) on feeders & convoyeurs| 18% Consommation d'énergie |
| Product Shape Index (Cubicité)| Standard Cone Crusher Output| Interparticle Crushing in Hydraulic Cone| +25% Improved Cubicity |
| Temps moyen entre les pannes (MTBF)| ~450 operating hours| ~1200 operating hours| +167% Fiabilité |
| Total Footprint Requirement| MultiStage Separate Units| Single Integrated Plant Design| 35% Espace nécessaire |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 150 TPH à 1,200 TPH nominal throughput on BF slag (Bulk Density ~1.6 t/m³).
Exigences d'alimentation: Total connected load from 350 kW à 900 kW selon configuration; primary crusher motor typically 160400 kW.
Spécifications matérielles: Crusher frames constructed from welded steel plate (minimum S355J2). Highwear components utilize multialloy castings or ceramic composites.
Dimensions physiques (Configuration typique): Longueur (~35m) x Width (~12m) x Height (~9m). Designed for flat concrete foundation or modular skid mounting.
Plage de fonctionnement environnementale: Fully operable from 20°C to +45°C ambient temperature with optional heating/cooling packages for lubrication systems. IP65 rating on electrical panels.

6. SCÉNARIOS D'APPLICATION

Integrated Steel Mill – Slag Aggregate Production

Défi: A major mill’s legacy hammer mill system suffered from weekly breakdowns, producing flaky aggregate unsuitable for highvalue concrete applications, resulting in significant revenue loss.
Solution: Implementation of a turnkey Luxury Slag Crusher Plant featuring a primary impactor and secondary cone crusher with precise shaping controls.
Résultats: Plant availability increased from 94%. The consistent, cubical aggregate now commands a 22% price premium in the readymix concrete market. Payback was achieved in under 18 months through reduced maintenance costs and increased sales revenue.

Independent Slag Processing Contractor – Mobile Deployment

Défi: A contractor needed to process stockpiled slag at multiple remote sites but could not justify the capital for several fixed plants. Existing mobile units lacked the throughput and dust control for largescale contracts.
Solution: Deployment of a semimobile Luxury Slag Crusher Plant on modular skids, complete with integrated dust suppression and power pack.
Résultats: The plant was relocated between three sites within one year. Its consistent 400 TPH output and complianceready operation allowed the contractor to secure longterm tollprocessing agreements based on guaranteed performance metrics.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification:
Configuration standard: Includes primary jaw crusher, concasseur à cône secondaire, basic screening, and conveyor system.
Configuration améliorée: Adds hydraulic setting adjustment, advanced dust control system, VFDs on key components,
and full PLC automation with SCADA interface.
Premium Configuration: Fully customized system including metal detection/removal,
automated liner wear monitoring,
and remote diagnostic telematics.

Fonctionnalités facultatives: Tramp metal detection systems,
acoustic enclosures,
winterization packages,
different screen media types (polyuréthane,
piano wire),
extended discharge conveyors.

Forfaits de services
Proactive Maintenance Plan: Scheduled inspections,
predictive analytics based on operational data,
and guaranteed spare parts availability.
Contrat de service complet: Includes all labor,
parts,
and planned component replacements (par ex.,
doublures,
roulements) for a fixed costperton processed.

Options de financement: Capital lease agreements,
locations simples,
and project financing solutions are available through accredited partners to match your cash flow requirements.

8\. FAQ

T1:
Is this plant compatible with our existing feed system
and downstream material handling?
UN:
Our engineering team conducts a full review of your interface points
(feed hopper height/discharge conveyor specs)
. The plant is designed with adaptable connections
to integrate into most existing layouts.

T2:
What is the expected operational impact during installation
et mise en service?
UN:
Pour un nouveau site,
we manage turnkey installation
. For retrofit scenarios,
we develop a phased implementation plan minimizing disruption
, typically requiring a scheduled shutdown of 710 joursfor mechanical tieins
.

T3:
How does the equipment pricing structure work?
UN:
Pricing is projectspecific based on required capacity
and configuration. We provide firm lumpsum quotations covering equipment supply ,
mise en service ,
and initial operator training.

T4:
What kind of operator training is provided?
UN:
We offer comprehensive onsite training covering normal operation ,
dépannage ,
procédures de sécurité ,
and basic preventive maintenance for your operations
and maintenance teams.

Q5:
Quel est le délai de livraison habituel à partir de la passation de la commande
to delivery?
UN:
Lead times vary by complexity .
Pour les configurations standards ,
expect 1624 semaines.
We provide detailed project schedules upon inquiry .

Q6:
Can you guarantee final product specifications?
UN:
Oui .
Based on your feed material analysis ,
we will provide performance guarantees for throughput capacity ,
product gradation curves ,

power consumption per ton.

Q7:
Les pièces de rechange sont-elles facilement disponibles?
UN:
We maintain strategic global inventories of critical wear
and mechanical parts.
Our service network can typically dispatch priority parts within 2448 heures.