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 and frequent clogging from uncrushable material halt your entire processing line, coûtant des milliers de dollars par heure en perte de production et de main d'œuvre.
Usure excessive & Coûts d'entretien: Standard crushers rapidly deteriorate when processing highly abrasive slag, leading to premature failure of liners, marteaux, and rotors. The resulting parts replacement and unplanned maintenance erode your profit margins.
Taille du produit final incohérente: Poorly controlled crushing results in uneven aggregate size distribution, reducing the market value of your slag product and limiting its application in highspecification construction or cement blending.
Complexité opérationnelle élevée & Risk: Reliance on multiple, nonintegrated units for feeding, écrasement, dépistage, and metal recovery increases manpower needs, risques pour la sécurité, and points of potential failure.

Is your current setup delivering the reliable throughput and product quality required for profitability? La solution réside dans un objectif conçu slag crusher plant processing plant.

2. APERÇU DU PRODUIT

UN slag crusher plant processing plant is a stationary or semimobile integrated system designed specifically for the reduction, dépistage, and separation of metallurgical slag (haut fourneau, four à acier). Il transforme grand, irregular slag feed into precisely graded aggregates for sale or further use.

Flux de travail opérationnel:
1. Réception primaire & Présélection: Runofpile slag is fed via loader into a robust hopper with a grizzly section to bypass fine material.
2. Primaire & Réduction de taille secondaire: A heavyduty jaw crusher performs initial breaking. A secondary impactor or cone crusher then reduces the material to the target size range.
3. Criblage des matériaux & Classification: Les tamis vibrants séparent les matériaux concassés en fractions de produit spécifiées (par ex., 05mm, 510mm, 1020mm).
4. Récupération de métaux (Facultatif): Overband magnets or magnetic head pulleys extract remaining ferrous metal from the crushed stream for recycling revenue.
5. Stockage & Expédition: Graded aggregates are conveyed to designated stockpiles for loadout.

Champ d'application: Traitement du laitier de haut fourneau (BFS), voler un coup (AVC LD), laitier de ferroalliage, et autres agrégats minéraux non métalliques.
Limite clé: Not designed for primary rock mining or processing extremely hard virgin rock; optimal performance requires feed material within specified hardness (Échelle de Mohs) and size parameters.

3. CARACTÉRISTIQUES PRINCIPALES

HeavyDuty Reciprocating Plate Feeder | Base technique: Controlled volumetric flow with adjustable stroke | Avantage opérationnel: Ensures even, chokefree material delivery to the primary crusher, preventing surges and overloads | Impact sur le retour sur investissement: Eliminates crusher stalls; increases overall plant throughput by up to 25% versus vibratory feeders in sticky slag conditions.

Manganese Steel Crusher Liners | Base technique: Workhardening austenitic manganese steel construction | Avantage opérationnel: Liners gain hardness upon impact, dramatically extending service life under severe abrasion | Impact sur le retour sur investissement: Réduit la fréquence de remplacement du revêtement de 4060%, réduisant les coûts d'inventaire des pièces et les temps d'arrêt pour maintenance.

Integrated Metal Separation System | Base technique: Permanent overband magnet with selfcleaning belt | Avantage opérationnel: Automatically recovers residual tramp metal during processing | Impact sur le retour sur investissement: Generates ancillary revenue from scrap metal; protège les concasseurs en aval des dommages; improves final product purity.

Système de contrôle PLC centralisé | Base technique: Contrôleur logique programmable avec interface homme-machine (IHM) panneau | Avantage opérationnel: Allows singleoperator monitoring and control of entire plant flow from a protected cabin | Impact sur le retour sur investissement: Réduit les besoins en main d’œuvre; enables quick troubleshooting; provides production data for efficiency analysis.

Conception modulaire montée sur patins | Base technique: Patins en acier de construction préassemblés pour les composants majeurs | Avantage opérationnel: Significantly reduces onsite civil work and installation time | Impact sur le retour sur investissement: Réduit les coûts d’installation d’environ 30% and allows for potential relocation or plant expansion.

HeavyDuty Vibrating Screens with Deck Guards | Base technique: HighG force exciters and easily replaceable deck panels | Avantage opérationnel: Provides consistent sizing efficiency even with damp or fine slag materials; guards contain fly rock | Impact sur le retour sur investissement: Ensures onspec product yield exceeding 95%, maximizing sales value; enhances operator safety.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Circuit de concassage de base) | Notre solution pour une usine de broyage de scories | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité du système| ~7580% (frequent stops for clearing,confitures) |>92% (engineered flow control) |>15% Amélioration |
| Durée de vie du revêtement du concasseur primaire| 6090 jours (manganèse standard) |>180 jours (premium/workhardening) |>100% Amélioration |
| Tons Processed per ManHour| Lower due to multipoint operation |>25% plus haut (centralized control) |>25% Amélioration |
| Taux de récupération des métaux| Manual picking or basic magnet |>99% ferrous recovery (optimized placement) |>30% Improvement in purity/revenue |
| Installation & Temps de mise en service| 812 semaines (field assembly) |>57 semaines (conception de patin modulaire) |>~40% de réduction |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de traitement: Configurable à partir de 50 à plus 300 tonnes par heure (TPH).
Exigences d'alimentation: La charge totale connectée varie généralement de 150 kW à 450 kW selon la configuration de l'installation; supplied at 415V/50Hz or customized.
Spécifications matérielles: Fabriqué à partir d'acier de construction S355JR; critical wear components in AR400 abrasionresistant steel and Grade I manganese steel.
Options du concasseur primaire: Jaw Crusher sizes from 750x500mm up to 1200x1000mm feed opening.
Options de concasseur secondaire: Concasseur à percussion (for less abrasive BFS) up to Ø1400mm rotor diameter, or Cone Crusher (for highly abrasive steel slag).
Screen Specifications: Single or doubledeck vibrating screens from 1800x4800mm up to 2400x6000mm.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust suppression spray systems are standard.

6. SCÉNARIOS D'APPLICATION

Integrated Steel Plant – Slag Processing Yard Challenge:

A major steel producer was landfilling LD converter slag due to an inefficient old crushing circuit that produced inconsistent aggregate sizes and suffered constant hammer wear in the impactor.

Solution:

Implementation of a turnkey slag crusher plant processing plant featuring a deepchamber jaw crusher for primary reduction followed by a robust cone crusher for secondary crushing. A twostage screening system was integrated with powerful overband magnets.

Résultats:

The plant achieved a consistent product yield of over 200 TPH of highvalue aggregate sold to the local cement industry. Metal recovery increased revenue by an additional $50k annually. Planned maintenance intervals extended from monthly to quarterly.

Independent Aggregate Producer – Diversification

Défi:
A traditional quarry operator sought to diversify into industrial byproduct processing but needed a system capable of handling highly variable feed sizes without constant reconfiguration.

Solution:

A semimobile slag crusher plant on skids with a heavyduty apron feeder was selected alongside an impact crusher with hydraulic adjustment for quick product size changes.

Résultats:

The operator could now process both purchased demolition concrete et sourced steelworks slag using one flexible unit. Changeover between materials takes less than two hours through hydraulic settings adjustments only.

7. CONSIDÉRATIONS COMMERCIALES

Our solutions are offered across three tiers:

1. Standard Configuration Plant ($250500 000 $):
Includes core modules—feeder, concasseur à mâchoires primaire,tamis vibrant,and conveyors—for basic sizing operations.Optional features include magnetic separator,kit de suppression de poussière,and starter motor controls package.Service package includes commissioning plus oneyear parts warranty.

2.
3.Enhanced Recovery Plant ($500k $900k):
Adds secondary cone/impactor crushers,a multideck sizing screen,and automated metal separation systems.Optional features include finished product washing systems,tramp iron protection devices,and advanced PLC automation.Service package extends warranty coverage plus annual preventive maintenance inspections.Financing options available through partner institutions include equipment leasing plans starting at $8k/month.

4.Installation de traitement clé en main ($900k+):
Fully integrated system including receiving hoppers,bacs de surtension,total dust collection enclosure,and automated weighloading out system.Custom engineering available.Optional features include remote monitoring via SCADA systems.Service package includes full operational training,a dedicated service manager,and guaranteed spare parts delivery within agreed terms.Comprehensive project financing can be structured based on client credit profile.

\Financing terms subject to credit approval.Please inquire directly regarding current rates.

FAQ

1.Q:What types of raw feed size can your standard plants accept?
UN:The standard primary jaw configuration accepts feed lumps up to ~650mm edge length.Larger inlet sizes are available as an option.Precrushing may be advised if runofpile chunks exceed this dimension consistently

2.Q:Quel est le délai typique entre la passation des commandes et la mise en service?
A.For standard configurations lead time is typically between16and24weeks.This covers manufacturing,tests en usine,and shipment.Modular skid design reduces site installation time significantly compared traditional builtinplace plants

3.Q:What ongoing maintenance does this equipment require?
A.Daily visual inspections weekly greasing checks are required.Major planned maintenance involves periodic liner replacements based actual wear rates which we help predict using historical field data.A comprehensive preventive schedule provided

4.Q.How does this integrate with our existing conveyor stockpile system?
A.The plants are designed as complete circuits but can be adapted tie into existing infrastructure.We require details regarding existing conveyor heights capacities ensure proper interface engineering during design phase

5.Q.What kind power supply needed operate typical200TPHplant?
A.A200TPHslag crushing screening circuit typically requires total connected load approximately300kW.We recommend consulting local electrical engineer ensure adequate supply transformer capacity softstart systems minimize grid disturbance

6.Q.Are spare parts readily available long after purchase?
A.All critical wear parts common consumables stocked our central warehouse.We provide recommended initial spare parts list order ensure minimal downtime guarantee availability support throughout equipment lifecycle

7.Q.What aftersales service support included?
A.All installations include commissioning supervision operator training period.We offer tiered service contracts ranging emergency breakdown support scheduled preventive maintenance visits full annual inspection programs