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?
Faible débit & Temps d'arrêt élevés: Inefficient primary crushing creates a backlog, halting downstream processing and delaying material recovery. Every hour of unplanned downtime represents significant lost revenue.
Excessive Abrasion & Coûts d'entretien: The highly abrasive nature of slag rapidly wears down standard crusher components, conduisant à des remplacements fréquents de pièces, stocks élevés de pièces de rechange, and costly labor for unscheduled maintenance.
Unreliable Size Reduction: Inconsistent feed size and composition from slag heaps result in poor fragmentation. This causes chokeups, reduces crusher efficiency, and produces an uneven end product that hampers subsequent separation or sale.
Coûts opérationnels élevés: The combined effect of energyinefficient crushing, constant maintenance, and process delays erodes your profit margin on recovered metal and aggregate.

Is your current slag processing system a source of recurring cost and disruption? A purposeengineered slag crusher plant directly addresses these pain points by transforming waste handling into a reliable, profitable recovery operation.

2. APERÇU DU PRODUIT

A modern slag crusher plant is a stationary or semimobile integrated processing system designed specifically for the size reduction and liberation of metallic fractions from steel, cuivre, or ferroalloy slag. It transforms raw slag feed into a consistently sized aggregate for sale or further processing.

Flux de travail opérationnel:
1. Concassage primaire: Gros morceaux de scories (up to 1m³) are reduced to manageable sizes (typiquement <200mm) en utilisant un concasseur à mâchoires robuste ou un brise-impact.
2. Concassage secondaire & Libération: Material undergoes further reduction in a cone or impact crusher to liberate embedded metal beads from the mineral matrix.
3. Dépistage & Séparation: Crushed material is screened into specified aggregate fractions (par ex., 05mm, 520mm). Liberated metal is recovered via magnetic separators.
4. Manutention des matériaux: Conveyors transport both the cleaned aggregate and recovered metal to designated stockpiles for dispatch.

Champ d'application: Idéal pour les aciéries intégrées, mini-moulins, fonderies de cuivre, chantiers de traitement des scories, and recycling contractors handling blast furnace (petit ami) scories, four à oxygène basique (BOF) scories, four à arc électrique (AEP) scories, et scories non ferreuses.

Limites: Non conçu pour le traitement primaire du minerai ou la roche extrêmement dure (>250 Mpa). Feed material must be free of explosive contaminants and oversized tramp metal beyond the system’s designed protection limits.

3. CARACTÉRISTIQUES PRINCIPALES

Concasseur primaire robuste | Base technique: Mâchoires à haute teneur en manganèse avec angle de pincement optimisé | Avantage opérationnel: Poignées grandes, dalles irrégulières sans pontage; withstands extreme shock loads | Impact sur le retour sur investissement: Reduces primary breakdown time by up to 40%, lowering labor costs per ton processed.

Séparation des métaux intégrée | Base technique: Overband magnetic separator positioned postcrushing | Avantage opérationnel: Automatically extracts ferrous scrap from the crushed stream for direct sale | Impact sur le retour sur investissement: Creates a secondary revenue stream; protects downstream equipment from metal damage.

Systèmes de revêtement résistants à l'abrasion | Base technique: Wearresistant steel plates in feed hoppers, chutes, and impact zones | Avantage opérationnel: Extends service intervals for highwear components by 23x | Impact sur le retour sur investissement: Lowers annual spare parts expenditure and reduces maintenance downtime.

Système de contrôle PLC centralisé | Base technique: Automated process control with motor monitoring and fault diagnostics | Avantage opérationnel: Enables singleoperator oversight; provides clear alerts for jams or overloads | Impact sur le retour sur investissement: Optimise la consommation d'énergie; prevents catastrophic failures through early intervention.

Conception modulaire montée sur patins | Base technique: Preassembled modules on heavyduty frames | Avantage opérationnel: Reduces onsite civil work and installation time by approximately 60% | Impact sur le retour sur investissement: Faster commissioning leads to quicker return on investment; permet un déménagement futur de l'usine.

Système de suppression de poussière | Base technique: Buses de pulvérisation stratégiquement placées aux points de transfert | Avantage opérationnel: Maintains compliant airborne particulate levels without slurry creation | Impact sur le retour sur investissement: Avoids regulatory fines; preserves worker health and site cleanliness.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Solution standard de l'industrie | Notre solution pour une usine de broyage de scories | Avantage (% Amélioration) |
| : | : | : | : |
| Débit de tonnage| Standard aggregate crusher adapted for slag | Purposebuilt with reinforced rotors/jaws & conception de flux optimisée| +1525% sustained throughput |
| Durée de vie de la doublure| Standard manganese steel in critical zones| Multilayer wear packages with replaceable sections in all abrasion zones| +80120% durée de vie prolongée |
| Taux de récupération des métaux| Manual picking or postprocess magnetic separation| Inline magnetic separation integrated into crushing circuit| +95% ferrous recovery efficiency |
| Consommation d'énergie par tonne| Entraînements à vitesse fixe sur tous les moteurs| Entraînements à fréquence variable contrôlés par PLC (VFD) sur convoyeurs & les fans| 1015% consommation d'énergie |
| Temps moyen entre les pannes (MTBF)| Reactive maintenance schedules based on runtime| Predictive maintenance enabled by vibration & thermal sensors on major bearings| +30% increased MTBF |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 TPH à plus 300 TPH of raw slag feed.
Exigences d'alimentation: Charge totale connectée de 150 kW à 800 kW selon configuration; standard supply at 415V/50Hz/3Phase (autres tensions disponibles).
Spécifications matérielles: Primary crusher jaws manufactured from Mn18Cr2 alloy steel; liner plates from AR400/500 abrasionresistant steel; structural frames from heavyduty ISMB/ISMC sections.
Dimensions physiques (Dérapage typique): Module primaire environ. L12m x L4m x H5m. Full plant footprint varies with configuration.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 10°C à +45°C; indice de protection contre la poussière IP55 pour les panneaux électriques; can be equipped with coldweather or tropical packages as needed.

6. SCÉNARIOS D'APPLICATION

Steel Mill Slag Yard Retrofit | Défi: A midsized steel mill faced chronic downtime due to abrasive wear in its aging crusher, causing pileup of LD slag and lost metal recovery revenue. Manual hammering was frequently required to clear jammed material.| Solution: Installation d'un clé en main 120 TPH skidmounted slag crusher plant featuring an extraheavyduty jaw crusher and integrated overband magnet.| Résultats: A atteint un débit constant de 120 TPH. Metal recovery increased by 22%. Les coûts de maintenance annuels ont diminué d'environ 35% due to reduced wear part consumption.

Entrepreneur indépendant en traitement des scories | Défi: A contractor needed a mobile solution to process legacy slag piles at multiple sites but required higher capacity than typical mobile track plants offered.| Solution: Deployment of a semimobile modular slag crusher plant on portable skids, allowing relocation between sites with minimal reassembly.| Résultats: Plant was operational at a new site within one week of arrival. Traité plus 150,000 tons across three sites with consistent product sizing, enabling premium pricing for clean aggregate.

7. CONSIDÉRATIONS COMMERCIALES

Our slag crusher plants are offered in clear pricing tiers based on capacity and robustness:

Usine de service standard (Jusqu'à 100 TPH): For processed EAF or granulated slag with consistent feed size.
Usine robuste (100 – 200 TPH): For mixed BF/BOF slags with higher abrasion potential; comprend des forfaits d'usure améliorée.
Extra HeavyDuty Plant (200+ TPH): For largevolume integrated mills; features duplex crushing stages and full automation.

Fonctionnalités facultatives: Dust encapsulation cabins, metal scrap cleaning drums (for cleaner scrap), advanced metal detectors, systèmes de graissage automatisés.
Forfaits de services: Plans de garantie prolongée, annual inspection contracts guaranteed spare parts kits based on your projected tonnage.
Options de financement: We work with accredited partners to offer equipment leasing plans or term loans tailored to capital expenditure cycles common in metallurgical processing industries.

8. FAQ

1. Q: Is your plant compatible with our existing material handling equipment?
UN: Oui. Our engineering team will review your current conveyor heights discharge points during the design phase Infeed hopper heights discharge conveyor trajectories are customized ensure seamless integration

2. Q What is the expected operational impact during installation commissioning?
A For skid mounted plants typical onsite installation electrical connection takes weeks Minimal disruption expected as most assembly testing is completed prior delivery

3 Q How do you guarantee the claimed wear life for components?
A Wear life projections are based historical data specific alloy specifications We provide guaranteed minimum tonnage figures for key wear parts backed commercial terms

4 Q What training provided for our operations maintenance staff?
A We include comprehensive onsite training covering normal operation routine maintenance troubleshooting safety procedures Documentation includes detailed manuals parts lists

5 Q Are there financing options available that align with our fiscal planning?
A Yes We offer several financing structures including operating leases capital leases term loans These can structured match cash flow generation from your recovered materials

6 Q Can the plant handle wet or sticky slag materials?
A While designed primarily dry processing we can incorporate specific design modifications such cascading feed systems non stick liners additional screening stages address challenging material characteristics

7 Q Quel est le délai de livraison à partir de la mise en service de la passation des commandes?
A Lead times vary capacity customization Typical lead time ranges months Standard configurations may be available shorter periods depending current production schedule