1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Gestion des scories, un volume élevé, sous-produit abrasif, presents persistent operational and financial challenges. Vivez-vous:
Coûts d'élimination élevés & Responsabilité: Les frais de mise en décharge des scories non traitées augmentent, and environmental regulations are tightening, creating longterm liability.
Récupération de matériaux inefficace: Valuable metallic content trapped within slag represents lost revenue and wasted resources when not properly liberated.
Temps d'arrêt excessif & Entretien: Standard crushers not engineered for extreme abrasion suffer rapid wear on liners and components, conduisant à de fréquents, arrêts imprévus.
Goulots d'étranglement dans le flux de matériaux: Inconsistent feed size reduction creates downstream processing issues for screening and sorting systems, limiter le débit global de l’usine.
Espace & Contraintes logistiques: Stockpiling raw slag consumes valuable yard space and complicates material handling logistics.

What if your operation could transform this costly byproduct into a highvalue aggregate or recover significant metal content, all while achieving greater equipment uptime? The solution lies in purposebuilt processing equipment.

2. APERÇU DU PRODUIT

A Private Label Slag Crusher Plant is a turnkey mineral processing system engineered specifically for the size reduction and liberation of metallurgical slag (haut fourneau, four à acier, cuivre, etc.). En tant qu'usine OEM, we manufacture complete plants that can be branded under your company’s private label.

Flux de travail opérationnel:
1. Concassage primaire: Alimentation en scories de grande taille (up to 1m³) is reduced by a robust jaw crusher or impactor designed for high shock loads.
2. Ferrous Metal Recovery: Primary crushed material passes over a powerful overhead magnetic separator to extract liberated ferrous scrap.
3. Concassage secondaire/tertiaire: Further size reduction via cone crushers or impact crushers with specialized liners achieves the target aggregate gradation.
4. Projection finale & Tri: Material is classified by vibrating screens; additional eddy current or sensor sorters can be integrated for nonferrous metal recovery.
5. Stockage: Sized aggregate products are conveyed to designated stockpiles for sale or utilization.

Champ d'application: Idéal pour les aciéries, fonderies, fonderies de métaux, entrepreneurs en traitement des scories, et producteurs de granulats spécialisés dans les sous-produits industriels.
Limites: Plant configuration must be matched to specific slag characteristics (indice d'abrasion, teneur en humidité, metallic percentage). Not designed for primary rock mining or extremely plastic/sticky materials.

3. CARACTÉRISTIQUES PRINCIPALES

Rotor robuste & Éléments d'impact | Base technique: Highinertia rotor design with martensitic/ceramic wear parts | Avantage opérationnel: Sustained crushing force against highly abrasive slag with dramatically extended service intervals | Impact sur le retour sur investissement: Réduit les coûts de remplacement des pièces d'usure jusqu'à 40% and associated labor downtime.

Circuit de séparation des métaux intégré | Base technique: Strategically placed magnetic drums/rolls and optional eddy current system | Avantage opérationnel: Continuous recovery of ferrous and nonferrous metals directly within the crushing circuit | Impact sur le retour sur investissement: Creates a direct revenue stream from recovered metal; protects downstream crushers from tramp metal damage.

Liner Optimization Package | Base technique: CADoptimized liner profiles in reinforced manganese steel or composite alloys | Avantage opérationnel: Maintains consistent feed opening and product gradation throughout liner life | Impact sur le retour sur investissement: Maximizes throughput tonnage per liner set and reduces number of changeouts annually.

Graissage centralisé & Surveillance des conditions | Base technique: Automated lubrication systems with sensor points for vibration and temperature | Avantage opérationnel: Ensures critical bearings receive proper lubrication in highdust environments; permet une détection précoce des défauts | Impact sur le retour sur investissement: Empêche les défaillances catastrophiques des roulements, une des principales causes de temps d'arrêt imprévus prolongés.

Conception d'usine modulaire | Base technique: Structures boulonnées avec goulottes et passerelles préfabriquées | Avantage opérationnel: Significantly reduces site installation time and civil engineering costs | Impact sur le retour sur investissement: Faster commissioning from delivery to production—often within weeks instead of months.

Suppression de la poussière & Système de confinement | Base technique: Nozzle arrays at transfer points paired with dusttight shrouding | Avantage opérationnel: Maintains regulatory compliance for particulate emissions and improves site working conditions | Impact sur le retour sur investissement: Avoids potential fines and work stoppages due to environmental or safety violations.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Usine de granulats génériques) | Solution d'usine de broyeur de scories de marque privée | Avantage (% Amélioration) |
| : | : | : | : |
| Liner Life in Abrasive Slag Duty | 6090 days typical operation before changeout required. >120 days documented in field data through optimized design & matériels. >33% augmenter |
| Taux de récupération métallique (Ferreux)| Single overband magnet after primary crushing only.| Multistage magnetic separation at primary discharge & final screen feeds.| Jusqu'à 15% higher recovery via liberation of locked metals. |
| Total Plant Availability (Temps de disponibilité) |>85% availability due to reactive maintenance schedules.| >92% target availability through designedforduty components & monitoring.| ~8% increase in productive operating hours annually. |
| Installation & Calendrier de mise en service |>12 weeks from delivery to full operation for fixed foundation plants.| ~68 weeks utilizing modular skid design with preassembled sections.| ~40% reduction in installation labor cost & faster ROI commencement. |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 TPH à plus 400 Laitier traité TPH.
Exigences d'alimentation: Puissance totale installée de la centrale 150 kW à 800 kW selon configuration; tension selon les spécifications du client (par ex., 400V/50Hz ou 480V/60Hz).
Spécifications matérielles:
Revêtements de concasseur: Acier au manganèse (14%18%), Chromium Iron Alloy, or composite ceramic inserts.
Chute & Porter des doublures: AR400 Steel minimum; optional AR500 or ceramic tile lining.
Acier de construction: S355JR grade for main frame and conveyors.
Dimensions physiques (Exemple 150 Usine TPH): Module primaire environ. L12m x W4m x H6m; secondary/screening module approx. L15m x W5m x H7m.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust protection rating standard IP55 for electrical components.

6. SCÉNARIOS D'APPLICATION

Défi du chantier de traitement des scories d’aciérie:

A major integrated steel mill faced rising landfill costs for aircooled blast furnace slag (BFS) and needed to recover contained pig iron beads.Solution:
Implementation of a turnkey Private Label Slag Crusher Plant featuring a heavyduty jaw crusher, deux étapes de séparation magnétique, and a cone crusher for cubical aggregate production.Résultats: Landfill diversion of 300,000 tons/year achieved; recovered iron generates $1.2M+ annual revenue; crushed BFS sold as railroad ballast aggregate.

Défi des producteurs de granulats indépendants:

An aggregate supplier sought to diversify its product line into premium industrial aggregates but found its existing limestone crushing plant suffered excessive wear when processing purchased steel slag.Solution:
A dedicated secondary/tertiary slag crushing circuit was supplied as a modular addition to their existing operation.Résultats: Enabled entry into the highmargin slag aggregate market without crosscontamination; wear costs on the new circuit were contained within projected budgets due to specialized liners.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Capital cost is configurationdependent.
Étage 1 (Basic Liberation): Concassage primaire + magnetic separation only.
Étage 2 (Full Aggregate Production): Primaire + Concassage secondaire + dépistage + full metal recovery.
Étage 3 (Complete Beneficiation): Includes tertiary crushing for specialty grades + advanced nonferrous sorting.
Fonctionnalités facultatives: Dust suppression packages automation control systems (Automate/SCADA), onboard power generation sets special wear monitoring systems extended conveyor lengths.
Forfaits de services: Standard offerings include commissioning supervision operator training annual preventive maintenance inspections spare parts kits.
Options de financement: We work with international export credit agencies project finance partners offer leasetoown structures typical terms range from months.

8.FAQ

Q What analysis do you require configure the correct plant our specific type?
A We require minimum kg sample material conduct Bond Abrasion Index tests chemical analysis determine metallic content recommend optimal crushing stages separator strengths.

Q How does plant handle wet sticky slag conditions?
A Configurations include feed prescreening grizzly sections impact crusher designs resistant buildup specific chute designs steeper angles vibratory feeders prevent bridging.

Q Quel est le délai de livraison typique?
A For standard modular designs lead time ranges months exworks depending complexity confirmed order receipt Custom engineering may extend timeline slightly.

Q L'équipement existant peut-il être intégré dans une nouvelle usine?
A Yes feasibility study conducted evaluate compatibility conveyors screens etc New core crushing modules engineered interface seamlessly.

Q What warranty provided key components?
A Structural components carry year warranty against defects Rotors shafts bearings carry year warranty Major crusher frames carry year warranty Specific terms outlined final contract.

Q Are operational manuals spare parts lists provided private label branding?
A Yes complete documentation including parts drawings maintenance schedules provided your branding ensuring your service team fully supported.

Q Offrez-vous des garanties de performance?
A Yes we provide guaranteed minimum throughput capacity product gradation based agreed feed material specifications pilot test results.