1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

La gestion des scories est un goulot d'étranglement persistant avec des coûts tangibles. Êtes-vous confronté à ces défis opérationnels?
Temps d'arrêt imprévus: Frequent clogging and abrasive wear in standard crushers lead to unscheduled maintenance, halting your entire material flow.
Coût opérationnel élevé: Excessive power consumption from inefficient crushing cycles and the recurring expense of replacing worn manganese steel components directly impact your bottom line.
Sortie incohérente: Variable feed size and moisture content result in an uneven final product, complicitating downstream processing or resale.
Espace & Intensité du travail: À plusieurs étages, fragmented crushing setups require a larger footprint and increased manual oversight for feeding and monitoring.

What if your slag processing could achieve higher throughput with lower specific energy consumption and predictable maintenance intervals? La solution réside dans un objectif conçu ensemble d'usine de concassage de scories.

2. APERÇU DU PRODUIT

UN ensemble d'usine de concassage de scories is a coordinated, semifixed or skidmounted system designed specifically for the primary and secondary reduction of blast furnace slag, voler un coup, or ferroalloy slag. Il transforme grand, irregular slag lumps into a calibrated aggregate for use in construction, additifs pour ciment, or road base materials.

Flux de travail opérationnel:
1. Alimentation & Présélection: Runofplant slag is fed via hopper; an integrated grizzly or prescreen removes fine material to bypass unnecessary crushing.
2. Concassage primaire des mâchoires: A robust jaw crusher performs the initial breakage of large lumps (jusqu'à 8001000mm) into manageable pieces (150200mm).
3. Secondary Cone/Roll Crushing: A secondary cone or roll crusher further reduces the material to the target product size (typically 020mm or 040mm).
4. Projection finale & Tri: Vibrating screens classify the crushed output into specified fractions, with oversize material recirculated.
5. Manutention des matériaux: Conveyors transport both feed and final product between stages and to stockpiles.

Champ d'application & Limites:
Portée: Idéal pour les aciéries intégrées, fonderies, chantiers de traitement des scories, and aggregate producers handling metallic byproducts. Effective on aircooled blast furnace slag and basic oxygen furnace (BOF) scories.
Limites: Not designed for primary rock mining or extremely highsilica content materials. Performance on very wet, sticky slag may require predrying or specialized feed arrangements.

3. CARACTÉRISTIQUES PRINCIPALES

Concasseur à mâchoires robuste | Base technique: Cinématique optimisée & high inertia flywheels | Avantage opérationnel: Sustained high force for breaking toughest slag lumps without stalling; reduces peak motor loads | Impact sur le retour sur investissement: Lower risk of unplanned stoppage; extends component life by 3040% basé sur des données de terrain

Système de revêtement résistant à l'abrasion | Base technique: Manganese steel with workhardening properties & strategic wear protection plates | Avantage opérationnel: Liners maintain profile longer under extreme abrasion, assurer un réglage cohérent des écarts et une gradation des produits | Impact sur le retour sur investissement: Reduces liner replacement frequency; documented savings of 1822% on consumables per ton crushed

Integrated Scalping & By-pass | Base technique: Precrushing grizzly screen with dedicated fines conveyor | Avantage opérationnel: Removes subsize material before primary crushing, increasing effective capacity and reducing wear on crusher chambers | Impact sur le retour sur investissement: Improves overall plant throughput by up to 15%; lowers specific energy cost (kWh/tonne)

Graissage centralisé & Points de surveillance | Base technique: Manifolded lubrication lines for all major bearings with accessible check points | Avantage opérationnel: Permet de sécuriser, rapid routine maintenance during planned stops; ensures critical components are properly lubricated | Impact sur le retour sur investissement: Minimizes lubrication time by approximately 50%; prevents costly bearing failures

Modular Skid Base Assembly | Base technique: Prealigned crushers, supports de moteur, and conveyors on a single structural steel base | Avantage opérationnel: Reduces civil works and onsite assembly time; simplifies foundation requirements and future relocation | Impact sur le retour sur investissement: Cuts installation costs by an estimated 25%; accelerates timetooperation

Adjustable Discharge Setting Mechanism | Base technique: Hydraulic or mechanical shim adjustment system on secondary crusher | Avantage opérationnel: Allows operators to finetune final product size quickly to meet varying customer specifications without major downtime | Impact sur le retour sur investissement: Increases plant flexibility; enables premium pricing for sized fractions

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Usine de concassage générique) | Our Slag Crusher Plant Assembly Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Availability for Slag Duty (%)| ~8285% due to wearrelated stops| Consistently exceeds 92% disponibilité| +810% une disponibilité plus productive |
| Durée de vie du concasseur primaire (Tons/Liner Set)| Très variable; souvent 120,000 tonnes| +50% durée de vie plus longue |
| Consommation d'énergie spécifique (kWh/tonne)| ~1,8 2.2 kWh/Ton for equivalent reduction| Réalise 1.5 1.7 kWh/Ton through optimized flow| ~1520% lower energy cost |
| Installation & Temps de mise en service| 812 weeks with significant field labor| Environ 46 weeks with skidmounted modules| ~4050% faster deployment |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 TPH à plus 300 TPH de laitier traité.
Feed Size Acceptance: Up to 1000mm lump size (dépend du modèle).
Gamme de tailles du produit final: Adjustable from 010mm to 060mm.
Exigences d'alimentation: Charge totale connectée généralement entre 150 kW à 450 kW (400V/50 Hz ou comme spécifié). Main drives utilize hightorque electric motors.
Spécifications matérielles: Primary wear parts manufactured from premium grade Mn18Cr2 / Mn22Cr2 steel; cadres structurels en acier robuste S355JR.
Dimensions physiques (Dérapage typique): Varie selon la capacité; par ex., a standard layout can be approximately L25m x W8m x H6m at its highest point.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; les connexions du système de suppression de poussière sont standard.

6. SCÉNARIOS D'APPLICATION

Recyclage intégré du parc à scories des aciéries

Défi: A major steel producer faced escalating landfill costs for BOF slag and needed to create a saleable road base material but experienced constant jamming in their existing impacttype crusher due to uncrushable metallic inclusions.
Solution Implementation of a tailored [ensemble d'usine de concassage de scories] featuring a deepchamber jaw crusher as primary stage followed by a cone crusher with tramp release system.
Results Metallic “tramp” iron is now ejected automatically without causing damage. L'usine produit plus de 250 TPH of certified aggregate, turning a waste cost into revenue stream within an estimated payback period of under two years.

Entrepreneur indépendant en traitement des scories

Challenge A contractor processing varied feedstock from multiple sources required mobility between sites but could not afford the output inconsistency of portable generic crushers.
Solution Deployment of a semiskidded [ensemble d'usine de concassage de scories] designed for partial disassembly/reassembly using modular conveyors and prewired power units.
Results The contractor reduced site setup time by over two weeks per move while maintaining consistent product quality across different slag types—documented production variance fell below ±5%.

7. CONSIDÉRATIONS COMMERCIALES

Notre [slag crusher plant assemblies] are offered in clear pricing tiers based on capacity:

Standard Range (50 – 120 TPH): Costeffective configuration ideal for smaller yards or dedicated process lines.
Fonctionnalités facultatives: Basic dust suppression kit manual adjustment systems
Forfait Services: Recommended annual inspection plan

HighCapacity Range (120 – 250 TPH): Most common configuration featuring full automation potential hydraulic adjustment
Fonctionnalités facultatives: Advanced PLC control panel metal detector magnet separator automated lubrication
Forfait Services: Comprehensive multiyear service agreement including liner change support

Financing Options Available capital expenditure can be facilitated through established equipment financing partners offering leaseto own structures or term loans typically over three five sevenyear periods subject to credit approval This allows you preserve working capital while implementing productivity gains immediately

8.FAQ

Q What if my incoming feed size varies significantly daytoday?
A The heavyduty jaw primary stage in our [ensemble d'usine de concassage de scories] is selected with ample gape opening allowing it accept large variation without bridging Prescreening further stabilizes flow ensuring consistent loading secondary stage

Q How does this system handle residual metal within the slag?
A We recommend optional integration permanent overhead magnetic separator positioned before primary crushing Additionally our secondary cone designs often include hydraulic clearing systems that safely discharge uncrushable tramp metal protecting internal components damage

Q What typical installation foundation required?
A For skidmounted assemblies requirement simplified generally limited reinforced concrete pads sufficient support total dynamic load Detailed civil drawings provided part engineering package facilitate local contractor preparation

Q Can existing conveyors other equipment integrated new plant?
A Yes integration possible requires review specifications during quotation phase ensure compatibility transfer points power supply Control systems can designed interface existing plant SCADA

Q What expected delivery lead time after order placement?
A For standard configurations lead time typically ranges between weeks depending complexity Customizations may extend this period detailed schedule provided upon project initiation