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 or undersized crushing circuits create a backlog, delaying material handling and tying up valuable site space. Every hour of crusher downtime impacts downstream processing revenue.
Usure excessive & Coûts d'entretien: La nature abrasive des scories dégrade rapidement les composants standard du concasseur, entraînant des changements fréquents de doublure, arrêts de maintenance imprévus, and soaring spare parts expenditure.
Unreliable Size Reduction: Inconsistent feed size and variable slag hardness can cause plugging, poor discharge gradation, and product that fails to meet specification for resale or further processing.
Complexité opérationnelle élevée: Plants requiring multiple stages of prescreening, manual breaking, or secondary crushing add labor costs and points of failure.

La question centrale pour les directeurs d'usine est la suivante: comment obtenir une cohérence, highvolume slag reduction with predictable operating costs and minimal disruption? La réponse réside dans une usine de concassage de scories spécialement conçue.

2. APERÇU DU PRODUIT

A slag crusher plant is a stationary or semimobile integrated processing system designed specifically for the primary and secondary reduction of metallurgical slag (haut fourneau, four à acier). Il transforme grand, irregular slag chunks into a precisely graded aggregate for use in construction, base de route, or as a feedstock for further metal recovery.

Flux de travail opérationnel:
1. Alimentation & Présélection: Runoffurnace slag is fed via loader into a hopper, often with a grizzly section to bypass subsize material directly to the discharge conveyor.
2. Concassage primaire: A heavyduty jaw crusher or impact breaker applies compressive force to break down large slabs (souvent jusqu'à 1 mois et plus) into manageable fragments.
3. Transfert de matériel & Concassage secondaire: A network of belt conveyors transports material to a secondary cone crusher or impactor for final size refinement.
4. Dimensionnement & Stockage: The crushed product passes over vibrating screens to separate it into specified grades (par ex., 05mm, 520mm, 2040mm), which are then stockpiled via radial or stacker conveyors.

Champ d'application & Limites:
Portée: Idéal pour les aciéries intégrées, fonderies, parcs à ferraille, and dedicated slag processing facilities handling ferrous and nonferrous slags.
Limites: Not designed for primary rock mining or extremely highmoisture materials without preconditioning. Feed size must be compatible with the primary crusher’s inlet dimensions.

3. CARACTÉRISTIQUES PRINCIPALES

Concasseur primaire robuste | Base technique: Robust manganese steel jaws/liners with optimized nip angle | Avantage opérationnel: Handles extreme shock loads from irregular slag feed without failure; réduit le pontage | Impact sur le retour sur investissement: Higher uptime and lower risk of catastrophic damage versus modified quarry crushers.

Système de transport résistant à l'abrasion | Base technique: Lits d'impact aux points de chargement; SBR/antitear conveyor belting; hardened alloy pulley lagging | Avantage opérationnel: Dramatically reduces belt wear and puncturerelated stoppages | Impact sur le retour sur investissement: Les données de terrain montrent un 4060% increase in belt service life, cutting replacement costs and labor.

Scalping intégré & By-pass | Base technique: Grizzly feeder or vibrating prescreen section before primary crusher | Avantage opérationnel: Removes fines and subsize material from the crushing circuit, augmentation de la capacité effective | Impact sur le retour sur investissement: Prevents crusher overload and reduces energy consumption per ton of processed material.

Système de contrôle PLC centralisé | Base technique: Automated startup/shutdown sequences with load monitoring and fault diagnostics | Avantage opérationnel: Enables operation by one person from a control cabin; provides clear alerts for maintenance triggers | Impact sur le retour sur investissement: Reduces labor requirements and allows for predictive maintenance scheduling to avoid unplanned downtime.

Conception structurelle modulaire | Base technique: Bolttogether heavy steel sections on prepared foundation | Avantage opérationnel: Faster installation and commissioning compared to weldedsite builds; permet une reconfiguration ou un déménagement futur | Impact sur le retour sur investissement: Cuts civil engineering costs and gets the plant operational weeks sooner.

Système de suppression de poussière déduite | Base technique: Buses de pulvérisation stratégiquement placées avec électrovannes liées au fonctionnement du convoyeur | Avantage opérationnel: Effectively controls dust at transfer points without overwetting the product | Impact sur le retour sur investissement: Ensures compliance with site environmental standards and protects worker health and machinery.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Modified Quarry Plant) | Notre solution pour une usine de broyage de scories | Avantage (% Amélioration) |
| : | : | : | : |
| Durée de vie de la doublure/pièce d’usure (Primaire) | 6090 days under severe duty | 120180 days under severe duty | +100% amélioration |
| Disponibilité du système (Temps de disponibilité) | ~8085%, arrêts mineurs fréquents| Cible >92%, designed for reliability| +812% augmentation absolue |
| Tons Processed per KWh| Varie considérablement; souvent inefficace| Optimized circuit reduces recrush| Jusqu'à 15% energy saving |
| Desired Product Yield| Often requires recrushing of oversize| Accurate sizing via tuned screen decks| Yield improvement of 510% |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 TPH à plus 300 Débit nominal TPH.
Exigences d'alimentation: Puissance totale installée généralement comprise entre 150 kW 450 kW selon configuration; supplied for 400V/50Hz or other industrial standards.
Spécifications matérielles: Crusher liners in Mn18Cr2/Mn22Cr2 steel; structural frames in S355JR grade steel; acier résistant à l'abrasion (AR400) at critical wear points.
Dimensions physiques (Exemple 150 Usine TPH): Surface au sol approximative de 35 m (L) x 18m (W); height ~12m. Custom layouts available.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; système de suppression de poussière conçu pour un fonctionnement efficace jusqu'à 80% humidité relative.

6. SCÉNARIOS D'APPLICATION

Recyclage intégré du parc à scories des aciéries

Défi: A major mill faced chronic bottlenecks in clearing aircooled blast furnace slag. Their existing setup caused excessive conveyor belt damage and produced inconsistent aggregate sizes rejected by their concrete block manufacturing customer.
Solution: Implementation of a turnkey slag crusher plant featuring an impact primary crusher for slab breaking and a secondary cone crusher closedcircuit with a tripledeck screen.
Résultats: Le débit a augmenté de 140%. Product gradation met specification consistently (>95% rendement). Belt replacement costs fell by an estimated $25,000 annually due to the redesigned transfer points.

Entrepreneur indépendant en traitement des scories

Défi: A contractor needed a mobile solution to process slag piles at multiple disused industrial sites. They required quick setup/teardown without sacrificing durability against abrasive material.
Solution: A semimobile skidmounted slag crusher plant with wheelmounted jaw crusher module and tracked screening module connected by extensible conveyors.
Résultats: Site deployment time reduced from weeks to days. The plant maintained an availability rate above 90% across three different site contracts, enabling the contractor to fulfill volumebased agreements reliably.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Investment scales with capacity and robustness.
Service standard: For lowervolume (<100TPH), less abrasive slags.
Robuste: Our most common specification for highvolume ferrous slag processing (>150TPH).
Projet clé en main: Includes civil works guidance, surveillance des installations, mise en service, et formation des opérateurs.
Fonctionnalités facultatives: Metal detection/magnetic separation modules postcrushing; systèmes de lubrification automatisés; télématique de surveillance à distance; enceintes acoustiques.
Forfaits de services: Tiered annual maintenance contracts are available covering scheduled inspections, priority spare parts supply discounts (typiquement 1020%), and technical support access.
Options de financement: We work with equipment financing partners to offer leasetoown plans or commercial loans tailored to capital expenditure cycles.

8. FAQ

1. Is your plant compatible with our existing feed system (par ex., excavator/dump truck)?
Oui. Hopper dimensions and heights are engineered based on your specific feeding equipment during the design phase to ensure efficient loading without modification.

2. Quel est le besoin attendu en main d’œuvre opérationnelle?
A welldesigned PLCcontrolled plant can be operated effectively by one control room operator per shift for normal running conditions.

3. How do you ensure wear part compatibility? Are they readily available?
We use industrystandard metric dimensions where possible (par ex., common jaw crusher models). All critical wear parts are stocked in our regional warehouses with guaranteed availability under service contracts.

4. Quel est le délai de livraison typique?
For standard configured plants after final design approval lead times range from XX weeks depending on complexity

5 Can we process wet or clinkerheavy slag?
The standard design handles aircooled denseslag optimally For very wet materials we recommend design modifications such as steeper hoppers screen deck heating elements which can be quoted as part of initial project scoping

6 What warranty is provided?
We offer X months warranty on all machinery against manufacturing defects Extended warranties are available through our service packages

7 Fournissez-vous des garanties de performance?
Yes we provide guaranteed minimum throughput capacity based on agreed feed material specifications as part of our turnkey project contracts