1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

La gestion des sous-produits de scories constitue un goulot d'étranglement opérationnel persistant avec des coûts tangibles. Êtes-vous confronté à ces défis?
Coûts d'élimination élevés & Responsabilité: La mise en décharge des scories est de plus en plus coûteuse et entraîne une responsabilité environnementale à long terme. Every ton processed onsite represents direct savings in haulage and tipping fees.
Récupération de matériaux inefficace: Le contenu métallique précieux piégé dans les scories représente une perte de revenus. Inefficient liberation and separation mean you are leaving profit in the waste stream.
Equipment Wear & Temps d'arrêt imprévus: Abrasive slag rapidly degrades standard crusher components, leading to frequent maintenance shutdowns, coûts de remplacement de pièces élevés, and unpredictable production halts.
Poussière & Noise Compliance: Processing slag generates significant dust and noise, creating worker safety concerns and increasing the risk of noncompliance with stringent site environmental regulations.

What if your slag handling system could transform this liability into a recoverable asset while operating reliably within modern environmental and efficiency standards?

2. APERÇU DU PRODUIT

The ROHS Compliant Slag Crusher Plant is a turnkey processing system engineered for the size reduction, liberation, and recovery of metallic fractions from industrial slag. It is designed for stationary or semimobile installation at smelters, aciéries, and metal recycling facilities.

Flux de travail opérationnel:
1. Alimentation & Présélection: Slag is fed via hopper and grizzly to remove fine fractions, directing only oversize material to the primary crusher.
2. Réduction de la taille primaire: A heavyduty crusher (généralement une mâchoire ou un impacteur) breaks down large slag chunks to a manageable size.
3. Libération du métal & Séparation: Crushed material undergoes magnetic separation to extract ferrous metals. Further screening and crushing cycles ensure optimal liberation.
4. Dimensionnement final & Stockage: The processed aggregate is screened into specified grades (par ex., 010mm, 1040mm) for sale or reuse, while recovered metal is prepared for recycling.

Champ d'application: Ideal for processing blast furnace (petit ami) scories, laitier de fourneau d'acier, and nonferrous slags from copper or lead production.
Limites: Not designed for primary rock mining or extremely highmoisture materials without predrying. Maximum feed size is determined by plant configuration.

3. CARACTÉRISTIQUES PRINCIPALES

Conception avancée de la chambre de concassage | Base technique: Cinématique et géométrie des pièces d'usure modélisées par ordinateur | Avantage opérationnel: Directs abrasive wear to replaceable liners, protects main machine body | Impact sur le retour sur investissement: Extends major overhaul intervals by up to 40%, reducing lifetime capital outlay.

Système de séparation magnétique intégré | Base technique: HighGauss permanent overband and drum magnets | Avantage opérationnel: Continu, automatic recovery of liberated ferrous metals directly from the crushing circuit | Impact sur le retour sur investissement: Increases metal yield by 1525%, transformer les déchets en revenus directs.

ROHSCompliant Dust Suppression | Base technique: Pressurized spray nozzles at transfer points with particle encapsulation technology | Avantage opérationnel: Suppresses airborne particulate at source, maintaining visible dust levels below 5 mg/m³ | Impact sur le retour sur investissement: Eliminates costly dustrelated work stoppages and ensures continuous regulatory compliance.

Amortissement acoustique & Enclosure System | Base technique: Composite sounddeadening panels on crusher and motors | Avantage opérationnel: Reduces operational sound pressure to below 85 dB(UN) à 1 mètre | Impact sur le retour sur investissement: Protects worker hearing, minimizes noise complaints from surrounding communities, avoids mitigation fines.

Spécification des composants robustes | Base technique: Use of AR400/500 steel for liners, highgrade castings for rotors/frames | Avantage opérationnel: Withstands extreme abrasion from sharpedged slag aggregates | Impact sur le retour sur investissement: Les données de terrain montrent un 60% improvement in wearpart life compared to standard quarry crushers, abaissement du coûtperton écrasé.

Graissage centralisé & Points de surveillance | Base technique: Manifolded lubrication lines to all critical bearings with diagnostic ports | Avantage opérationnel: Permet de sécuriser, entretien courant rapide sans démontage | Impact sur le retour sur investissement: Reduces scheduled lubrication downtime by 70% and prevents premature bearing failures.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Usine de scories conforme aux normes de l'industrie | ROHS Compliant Slag Crusher Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Taux de récupération métallique (%)| ~85% (estimé) |>95% (measured) |>10% Amélioration |
| Durée de vie des pièces d'usure (Heures) | ~8001200 hrs on liners |>2000 hrs on liners |>60% Amélioration |
| Contrôle des émissions de poussière| Basic bag filters or water sprays| Integrated multipoint suppression system |>80% Reduction in airborne particulates |
| Niveau d'émission sonore| ~95105 dB(UN)| 10 dB(UN) Réduction |
| Temps moyen entre les pannes (MTBF)| ~450 heures |>750 heures |>65% Amélioration |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de traitement: Configurable à partir de 50 TPH à 300 TPH.
Exigences d'alimentation: Moteur du concasseur primaire de 90 kW à 315 kW; puissance totale de l'installation en fonction de la configuration.
Taille d'alimentation maximale: Up to 700mm lump slag.
Tailles du produit final: Adjustable via screen decks; typically producing 05mm sand substitute, 520mm agrégat.
Spécifications matérielles: Primary frame construction from heavyduty steel plate; internal wear parts in AR400/500 steel; dust enclosure in galvanized sheeting.
Dimensions physiques (Configuration typique): Longueur ~25m x Largeur ~8m x Hauteur ~6m (hors trémie d'alimentation).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust suppression system rated effective up to 80% material moisture content.

6. SCÉNARIOS D'APPLICATION

Steel Mill – Blast Furnace Slag Processing

Défi: A major steel producer faced rising landfill costs for granulated BF slag and needed to create a saleable construction aggregate while recovering residual iron.
Solution: Installation d'un 200 TPH ROHS Compliant Slag Crusher Plant with twostage crushing and highintensity magnetic separation.
Résultats: Réalisé >96% récupération des métaux. Produit sur 450,000 tonnes par an de granulats de construction certifiés, eliminating disposal costs and generating new revenue streams. Payback period was under 24 mois.

Copper Smelter – Waste Stream Valorization

Défi: A smelter’s legacy slag piles contained locked copper units; traditional crushing methods were inefficient and created excessive dust emissions near site boundaries.
Solution: Deployment of a mobileconfiguration ROHS Compliant plant featuring enhanced dust control for onsite pile processing.
Résultats:Liberated an additional 34% copper content from old stockpiles for refining.Dust emissions remained within strict site limits throughout the project,demonstrating environmental compliance during remediation.

7. CONSIDÉRATIONS COMMERCIALES

Our ROHS Compliant Slag Crusher Plants are offered in three primary tiers:
1. Configuration standard: Concassage de noyau,séparation magnétique,and basic dust control.For operations with existing infrastructure.Capital cost range:$350k $800k USD based on capacity.
2. Configuration optimisée (Le plus courant): Includes advanced acoustic enclosures automated grease systems,and enhanced multipoint dust suppression.Recommended for new installations.$500k $1M USD range
3. Fully Integrated Modular Plant: Includes feed conveyor prescreening module fines handling system,and centralized PLC control.Easily relocated.$750k $1M+ USD

Optional features include metal fragmentizers secondary eddycurrent separators for nonferrous metals remote monitoring telemetry

Service packages range from annual inspection plans to fullcostperton operating agreements ensuring predictable maintenance budgeting

Financing options include equipment leasing capital loansand payforperformance models tied to recovered metal tonnage

8.FAQ

Q:What defines 'ROHS Compliant' in this context?
UN:The plant design specifically restricts the use of hazardous substances like lead mercury cadmium etc.in electrical components control systemsand paints ensuring the equipment itself meets international environmental directivesfor industrial machinery

Q Is this plant compatible with our existing conveyorand screening setup?
A Yes The plantis designed as modular skidmounted systemswith standardized discharge heightsand chute connectionsto interfacewith most existing material handling infrastructure Site surveysare conductedto confirm compatibility

Q How does the plant impact our operational manpower requirements?
A The centralized designand automated systems typically requirea crewof two operatorsfor monitoringand routine checks reducing labor intensity comparedto multiple standalone machines

Q What isthe expected timelinefrom orderto commissioning?
A For standard configurations deliveryis typically within16 weeks Commissioningand operator training requiresan additional2 weekson site dependingon foundationpreparation status

Q Des garanties de performance sont-elles fournies?
A Yes We provideguaranteesfor minimum throughput capacity maximum power consumptionand final product gradation basedon your specific feed material analysis