1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

La gestion des scories est un goulot d'étranglement persistant avec des coûts tangibles. Your operation likely faces these challenges: unprocessed slag piles consuming valuable yard space and representing lost revenue from recoverable metals; inconsistent feed size causing downstream processing inefficiencies and increased wear on conveyors and separators; excessive dust generation during crushing leading to environmental noncompliance, health risks, et les frais de nettoyage du site; premature equipment failure due to the highly abrasive nature of slag, resulting in unscheduled downtime and high parts replacement frequency; and the logistical expense of transporting uncrushed material offsite for processing.

Are these issues impacting your bottom line? How much production time is lost to maintenance? What is the true cost of noncompliance and inefficient metal recovery? Un objectif conçu ROHS Compliant Slag Crusher Plant is the systematic answer.

2. APERÇU DU PRODUIT

This is a stationary or semimobile crushing circuit specifically engineered for ferrous and nonferrous slag reduction. Il transforme grand, irregular slag feed from furnaces or stockpiles into a precisely graded aggregate for sale or a controlledsize feedstock for metal recovery processes.

Flux de travail opérationnel:
1. Réduction de la taille primaire: Gros morceaux de scories (jusqu'à 800 mm) are fed into a robust primary jaw crusher for initial breakage.
2. Séparation des métaux & Scalping: Crushed material passes over an overhead magnetic separator to remove liberated ferrous metals, followed by a vibrating grizzly to scalp out fines.
3. Concassage secondaire/tertiaire: Oversize material is conveyed to a secondary cone or impact crusher for further reduction to the target product size (typically 040mm).
4. Dimensionnement final & Stockage: The crushed product is screened via a multideck screen, with oversize recirculated and correctly sized material conveyed to stockpiles.

Champ d'application: Idéal pour les aciéries intégrées, fonderies de cuivre/nickel, fonderies, et chantiers de traitement de scories autonomes manipulant des hauts fourneaux (BFS) ou laitier de fourneau d'acier.
Limites: Not designed for primary rock mining or extremely highmoisture claybased materials without preprocessing.

3. CARACTÉRISTIQUES PRINCIPALES

Concasseur primaire robuste | Base technique: Mâchoires renforcées en acier au manganèse & roulements surdimensionnés | Avantage opérationnel: Sustained throughput of highly abrasive slag with minimal deformation or seizure risk | Impact sur le retour sur investissement: Reduces primary crusher replacement cycle by up to 40%, réduire le coût de la tonne

Séparation magnétique intégrée | Base technique: Overbelt selfcleaning electromagnet positioned postprimary crush | Avantage opérationnel: Earlystage removal of liberated ferrous metals protects downstream conveyors and crushers from tramp metal damage | Impact sur le retour sur investissement: Recovers valuable metal scrap directly and can reduce downstream maintenance costs by an estimated 1525%

ROHSCompliant Dust Suppression System | Base technique: Encapsulated transfer points with strategically placed fine mist spray nozzles using minimal water | Avantage opérationnel: Actively suppresses airborne particulate at source, maintaining workplace air quality standards | Impact sur le retour sur investissement: Mitigates risk of regulatory fines and reduces housekeeping labor by an average of 8 heures par semaine

Graissage centralisé & Surveillance des conditions | Base technique: Automated lubricant delivery to key bearing points with visual inspection ports | Avantage opérationnel: Ensures critical components operate within specified parameters, prolonger la durée de vie | Impact sur le retour sur investissement: Enables predictive maintenance, preventing catastrophic bearing failures that can cause 2472 hours of unplanned downtime

Modulaire, BoltTogether Design | Base technique: Prefabricated structural modules with flanged connections | Avantage opérationnel: Significantly reduces civil works and onsite assembly time compared to welded designs | Impact sur le retour sur investissement: Réduit les coûts d’installation d’environ 30% et permet une future reconfiguration ou une relocalisation de l'usine

HighAngle/LowSpeed Feed Conveyor | Base technique: Chevronpatterned belt with deep cleats operating at optimized speed | Avantage opérationnel: Prevents rollback of slabby slag material during inclined transport, ensuring consistent feed to the crusher hopper | Impact sur le retour sur investissement: Eliminates feedrelated stoppages, maximizing plant uptime and throughput consistency

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Solution standard de l'industrie | ROHS Compliant Slag Crusher Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Tonnage Processed per Maintenance Hour| 8001,000 tonnes/hour between scheduled stops| 1,2001,500 tonnes/hour between scheduled stops| +50% disponibilité opérationnelle |
| Efficacité de récupération des métaux (Ferreux)| ~8590% recovery rate| 9497% recovery rate via optimized magnet placement| +7% increase in reclaimed metal value |
| Émissions de poussières aux points de transfert| >50 mg/m³ (requiring additional control)| Constamment 60% reduction in particulate output |
| Consommation d'énergie par tonne| Varie considérablement; often not optimized| Engineered drive systems & efficient crusher chambers reduce draw| Les données de terrain montrent 812% kWh/tonne inférieur |
| Installation & Calendrier de mise en service| 46 semaines pour les installations à fondations fixes| 23 weeks for modular bolttogether plants| Temps de fonctionnement ~50 % plus rapide |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 TPH à plus 300 TPH.
Taille de l'alimentation: Maximum lump size up to 800mm x 1200mm.
Exigences d'alimentation: Charge totale connectée généralement entre 150 kW 450 kW selon configuration (380V/415V /50Hz/60Hz).
Spécifications matérielles: Revêtements de broyeur en acier au manganèse de première qualité (18%22%); cadres structurels en acier robuste S355JR; wear liners at chutes in AR400 steel.
Dimensions physiques (Configuration typique): Empreinte environ 25 m (L) x 15m (W) x 12m (H). La conception modulaire permet l'adaptation.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C. Dust suppression system effective up to 80% humidité relative.

6. SCÉNARIOS D'APPLICATION

Integrated Steel Plant Slag Yard Management

Défi: A major steel producer faced growing BOF slag stockpiles with inconsistent metal recovery. Manual sorting was inefficient, and their existing crusher suffered frequent liner failures.
Solution: Implementation of a turnkey ROHS Compliant Slag Crusher Plant with primary jaw crusher, concasseur à cône secondaire, and twostage magnetic separation.
Résultats: Achieved a consistent 25mm product for road base sales. Metal recovery efficiency increased from ~82% to 96%, adding significant revenue. Planned liner changes replaced unpredictable breakdowns.

Copper Smelter Tailings Reprocessing

Défi: Historical slag dumps contained locked copper particles but were too heterogeneous for costeffective processing with mobile equipment.
Solution: A semimobile ROHS compliant plant was installed onsite with highwear resistant impact crushers tailored for abrasive nonferrous slag.
Résultats: Les processus végétaux 200 TPH of legacy material. The controlled crushing size liberation improved downstream flotation recovery by 18%, turning a liability into a profitable operation.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification:
Configuration de base: Includes primary crushing, basic conveyor system, et tableau de commande électrique.
Configuration améliorée: Adds secondary crushing stage, séparateur magnétique(s), kit de suppression de poussière, and advanced PLC automation.
Solution clé en main: Full engineering design, soutien aux travaux de génie civil, surveillance des installations, mise en service, and operator training package.

Fonctionnalités facultatives: Metal detector prior to primary crusher; hot slag handling modifications; enceintes d'insonorisation; systèmes d'échantillonnage automatisés; télématique de surveillance à distance.

Forfaits de services:
Contrat de maintenance annuel: Inspections programmées, kits de lubrification,
10% discount on spare parts.Performance Care Package: Includes above plus quarterly vibration analysis,
guaranteed emergency response time,
fixedcost annual parts bundle.Options de financement: Structures de location de matériel,
renttoown agreements,
or project financing available through accredited partners typically over
36
60 termes du mois.

8.FAQ

Q:What defines 'ROHS Compliant' in this context?
UN:The plant design prioritizes environmental protection through integrated engineering controls.The dust suppression system ensures airborne particulate meets strict workplace exposure limits,and the electrical system components are specified without restricted hazardous substances per the EU directive.It signifies a plant built for modern regulatory compliance.

Q Can this plant process wet or clumpy slag?
A While designed for typical aircooled slag,surface moisture is managed by the dust suppression system.Highly saturated or claycontaminated material may require prescreening or blending with drier feed.Consult our engineering team for specific material testing recommendations.

Q How does this solution improve our overall metal recovery profitability?
A By positioning highintensity magnetic separation immediately after primary crushing,the system recovers clean liberated metal early.This prevents it from being repeatedly processed reducing degradation into fines which are harder to recover.The result is higher yield of premiumgrade scrap alongside protected downstream equipment.

Q What is the expected lifespan of key wear parts?
A Under normal operating conditions industry testing demonstrates primary jaw liners last
1200
1500 operating hours secondary concave/mantle sets last
1800
2200 hours.Wear life varies based on specific slag abrasiveness index(S.A.I)and throughput which we factor into our performance projections.

Q Are your plants compatible with our existing conveyor infrastructure?
A Yes.Engineering specifications include detailed interface points(feed height discharge height belt width capacity).We design transfer chutes and supports to integrate seamlessly with your current layout minimizing retrofit costs during procurement planning we require your site layout drawings

Q What training do you provide for our operations team?
A We provide comprehensive training covering safe startup/shutdown procedures routine maintenance checks troubleshooting common issues,and basic control system operation.Training occurs during commissioning using your actual plant Documentation includes full operational manuals parts lists schematic diagrams