1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Votre opération de manutention de scories est-elle un goulot d'étranglement persistant et une source de coûts cachés? Pour les directeurs d’usine et les entrepreneurs en ingénierie, les défis du traitement des scories métallurgiques sont multiples. Vivez-vous:
Temps d'arrêt excessif: Colmatage fréquent, pontage, and abrasive wear in primary crushing stages halting your entire material recovery line?
Débit imprévisible: Inconsistent feed size and composition from ladles leading to capacity fluctuations and missed processing targets?
Coûts opérationnels élevés: Premature failure of crusher components not designed for extreme abrasion, coupled with high energy consumption per ton processed?
Recovery Inefficiency: Inadequate liberation of metallic fractions from the slag matrix, leaving valuable material in your waste stream and reducing overall plant revenue?
Sécurité & Maintenance Burdens: Laborintensive clearing of jams and the risks associated with manual handling of large, irregular slag pieces?

Ces problèmes ont un impact direct sur vos résultats en raison de la perte de production, increased maintenance labor, and suboptimal metal recovery. La question centrale est: comment obtenir une fiabilité, highvolume slag reduction with predictable operating costs?

2. APERÇU DU PRODUIT: USINE DE BROYAGE DE SCORIES

A Slag Crusher Plant is a purposebuilt, système de traitement stationnaire ou semi-mobile conçu pour le primaire, secondaire, and sometimes tertiary reduction of aircooled or granulated metallurgical slag. Its function is to liberate entrapped metal (ferrous and nonferrous) from the slag matrix and produce a consistently sized aggregate for sale or further processing.

Flux de travail opérationnel:
1. Alimentation & Présélection: Runoffurnace slag is fed via loader or conveyor into a robust grizzly or scalping screen to remove fine material (30mm) contourner le concasseur primaire.
2. Concassage primaire: Matière surdimensionnée (+30mm to +500mm) enters a heavyduty jaw crusher or impact breaker designed to handle extreme shock loads and abrasion.
3. Séparation des métaux & Concassage secondaire: The crushed product is conveyed past an overhead magnetic separator to extract liberated ferrous metal. Remaining material may pass through a secondary cone or impact crusher for final sizing.
4. Dimensionnement final & Stockage: Material is screened into specified aggregate fractions (par ex., 05mm, 510mm, 1020mm) via vibrating screens and conveyed to stockpiles.

Champ d'application & Limites:
Portée: Idéal pour les aciéries intégrées, fonderies de cuivre, producteurs de ferroalliages, et chantiers de traitement de scories autonomes manipulant des hauts fourneaux (petit ami), four à oxygène basique (BOF), four à arc électrique (AEP), ladle, et scories non ferreuses.
Limites: Not designed for primary rock mining applications. Performance on extremely sticky or highmoisture slags may require predrying or specialized feed systems.

3. CARACTÉRISTIQUES PRINCIPALES

Concasseur primaire robuste | Base technique: Mâchoires en acier à haute teneur en manganèse & Cadre renforcé | Avantage opérationnel: Sustained performance under extreme shock loads from large, irregular slag pieces with minimal deformation | Impact sur le retour sur investissement: Reduces unplanned crusher downtime by up to 40% and extends jaw life by over 60% par rapport aux conceptions standards.

Circuit de séparation magnétique intégré | Base technique: Overband SelfCleaning Electromagnets positioned at optimal discharge points | Avantage opérationnel: Continu, automated recovery of liberated ferrous metal directly from the crushed stream without manual intervention | Impact sur le retour sur investissement: Augmente les taux de récupération des métaux de 1525%, creating a direct revenue stream from what was previously waste.

Système de flux de matériaux résistant à l'abrasion | Base technique: Revêtements en acier AR400/500 dans les trémies, chutes, and skirts; impact beds on conveyor load zones | Avantage opérationnel: Dramatically reduces wearrelated failures in highimpact areas, maintaining consistent flow geometry | Impact sur le retour sur investissement: Réduit les coûts annuels de remplacement du revêtement d’une moyenne de 35% and reduces conveyor belt damage.

Automatisation centralisée des API & Surveillance | Base technique: Programmable Logic Controller with HMI touchscreen for system control; motor current sensors and bearing temperature monitors | Avantage opérationnel: Enables oneoperator control of the entire plant with realtime alerts for abnormal conditions like overloads or blockages | Impact sur le retour sur investissement: Optimizes power consumption per ton by up to 20% through controlled sequencing; reduces required operational manpower.

Conception modulaire montée sur patins (Facultatif) | Base technique: Preassembled crusher modules on heavyduty structural skids with integrated walkways | Avantage opérationnel: Significantly reduces civil works requirements and onsite installation time by up to 70% | Impact sur le retour sur investissement: Faster commissioning accelerates timetorevenue; facilitates future relocation if site requirements change.

Dedicated Slag Crusher Plant Dust Suppression System | Base technique: Nozzle arrays at transfer points connected to a highpressure pump unit with moisture sensors | Avantage opérationnel: Effectively controls fugitive dust at source without overwetting material which can cause downstream handling issues | Impact sur le retour sur investissement: Ensures compliance with site environmental standards; protects other machinery from abrasive dust ingress.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Solution standard de l'industrie | This Slag Crusher Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité / Temps de disponibilité| ~7580%, frequent jamming/clogging incidents| >92%, engineered feed system & conception de la chambre de concassage| +15% disponibilité opérationnelle|
| Coût d'usure par tonne traitée| Grande variabilité; frequent liner/impeller changes| Predictable cost; extendedlife components documented| 35% réduction moyenne|
| Efficacité de récupération des métaux (%)| Manual picking postcrushing or singlestage magnetic separation| Multistage liberation with optimized magnetic separation points| +20% ferrous recovery yield|
| Consommation d'énergie (kWh/tonne)| Often overlooked; oversized motors running constantly| PLCcontrolled optimized start/stop sequences & VFDs on feeders| 18% réduction moyenne|
| Installation / Temps de mise en service| Extensive field fabrication & alignement (1216 semaines)| Pretested modular skids requiring connection only (68 semaines)| 50% site construction time|

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 TPH à plus 300 TPH de laitier traité.
Options du concasseur primaire: Curseur de mâchoire (900 x 600mm to 1500 x 1200mm) or Primary Impact Crusher with hydraulic adjustment.
Exigences d'alimentation: Charge totale connectée généralement entre 250 kW – 800 kW selon configuration; fourni pour 415V/3Phase/50Hz ou comme spécifié.
Spécifications des matériaux clés:
Crusher Jaws/Hammers/Blow Bars: Acier au manganèse de première qualité (1822% Mn).
Liners/Chutes/Wear Plates: Minimum AR400 Steel.
Structural Frames & Patins: HeavyDuty Pentaplate / IS2062 E350 Grade Steel.
Bande transporteuse: Minimum EP630/4 rated for abrasion resistance.
Dimensions physiques (Typical Modular Plant): Length ~40m x Width ~12m x Height ~9m (hors trémie d'alimentation).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 10°C à +45°C; dust suppression system maintains operation within PM10 emission standards.

6. SCÉNARIOS D'APPLICATION

Usine sidérurgique intégrée – Traitement des scories BOF

Défi: A major steel producer faced severe bridging in their existing crusher feed hopper when processing large BOF slag lumps (>800mm), provoquant des temps d'arrêt quotidiens. Metal recovery was inefficient using a single magnet after crushing.
Solution: Implementation of a custom Slag Crusher Plant featuring a vibrating grizzly feeder with stepped grizzly bars to break bridges ahead of a deepchambered jaw crusher. Two overband magnets were installed—one precrusher for loose metallics and one postprimarycrusher.
Résultats: Bridging incidents eliminated entirely. La disponibilité des plantes est passée de 78% à >94%. Ferrous metal recovery improved by 22%, paying back the system’s capital cost in under two years through recovered metal value alone.

Entrepreneur indépendant en traitement des scories

Défi: A contractor servicing multiple smalltomedium EAF mills needed a portable solution that could be relocated between sites every 1824 months but required consistent high throughput without lengthy setup times.
Solution: A fully skidmounted Slag Crusher Plant was supplied on four modular sections (feed module with scalper, primary crusher module, screening/magnet module). All modules featured quickdisconnect electrical/pneumatic connections.
Résultats: Relocation time between sites reduced from three months to four weeks due to minimal civil work required at new locations. Consistent throughput of ~120 TPH maintained across different site configurations.

7. CONSIDÉRATIONS COMMERCIALES

Our Slag Crusher Plants are offered in three primary tiers based on capacity and automation level:

1. Usine de service standard (<100 TPH): Focuses on core reliability with essential features like primary crushing and magnetic separation—ideal for smaller operations prioritizing capital efficiency.
2. Usine robuste (100 – .200 TPH):) Our most common configuration includes full abrasion protection package advanced PLC automation multistage sizing/screening—designed for maximum total costofownership savings in continuous operation
3.
4.HighCapacity/Turnkey System (>200 TPH):) Includes all heavyduty features plus optional secondary crushing stage automated sampler complete dust collection baghouse system project management services

Les fonctionnalités facultatives incluent:
Systèmes automatisés de lubrification à la graisse
Thermal camera monitoring for bearings
Advanced aggregate cubicity shaping kit
Onboard diesel generator power pack

Service Packages range from basic commissioning/spare parts supply upto comprehensive annual maintenance contracts including scheduled wear part replacement

Financing options including equipment leasing rentalpurchase agreements are available subjecttoqualification providing flexibilityincapitalexpenditureplanning

8.FAQ:

Q1 How do I determine if my specific typeofslag requiresajawcrushersoranimpactcrushersastheprimaryunitintheslagcrushersplants?
A1 The choice dependsonslag characteristics Jaw crushers are generally preferredforhighlyabrasive dense slagswithcompressivestrengthlikeaircooledBFslag duetotheirdirectforceandslowerspeed minimizing wear Impactors can offer higher reduction ratiosandbetter particle shapeforlessabrasive slags like someEAFslag We analyze your samplematerialin our labtoprovideadatabacked recommendation

Q2 Whatisthetypicalinstallationfootprintandfoundationrequirementsforaskidmountedslagcrushersplants?
A2 While significantly reduced comparedtotraditional plants level compacted groundoraminimalconcretethicknesspadissufficientforskid placement Major civil workislimitedtofeedhopperpitsandfinalproducttunnelconveyors if applicable Detailed foundation drawings are providedforsitepreparation

Q3 CananexistingslagcrushersplantsbeupgradedwithyourkeyfeaturesliketheenhancedmagneticcircuitorPLCautomations?
A3 Yes many components suchasoverbandmagnets advancedlinersandcontrol systems can be retrofitted ontoexistinginfrastructure Our engineers can conductanauditofyourcurrentsetupandproposephasedupgradestoimproveperformanceandROI

Q4 Howdoyouquantifythepotentialmetalrecoveryimprovementbeforepurchases?
A5 We conductarepresentativesampletestingprograminvolvinglaboratoryscalecrushingandmagneticseparationonyoursuppliedslag This generatesametallurgicalbalancereportprojectingliberationratesandrecoverypotentialwithdifferentmachineconfigurations providinganevidencebased forecast

Q5 Whatistheleadtimefromordertocommissioningforastandardheavydutyslagcrushersplants?
A6 Forstandarddesignsintheheavydutyrange leadtimesaveragebetweenfivesevenmonths This includesmanufacturing factorytesting disassemblyforshipmentandreassemblyonyoursite Modularskiddedunits reduceonsiteassemblytimebyoverhalfcomparedtopiecebuilt plants