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?
Débit peu fiable & Temps d'arrêt: Inconsistent feed size and tramp metal cause frequent jams in standard crushers, halting your entire material recovery line and delaying downstream processing.
Usure excessive & Coûts d'entretien: The highly abrasive nature of slag rapidly degrades standard manganese steel components, leading to unscheduled shutdowns and high spare part expenditures.
Inefficient Liberation of Valuables: Inadequate crushing fails to fully liberate metallic fractions (ferrous and nonferrous) from the slag matrix, leaving recoverable value in your waste stream and reducing overall plant revenue.
Poussière & Environmental Control Issues: Dry crushing processes generate significant fugitive dust, creating environmental compliance risks and unsafe working conditions for personnel.

If these issues are impacting your profitability, the central question is: comment obtenir une cohérence, highvolume slag reduction with lower operational costs and maximized metal recovery? La réponse réside dans un objectif conçu Usine de concassage de scories.

2. APERÇU DU PRODUIT

UN Usine de concassage de scories is a stationary or semimobile processing system specifically engineered for the primary, secondaire, et parfois concassage tertiaire de scories métallurgiques (haut fourneau, four à acier, cuivre, etc.). Its design prioritizes durability against abrasion and impact while ensuring efficient liberation of entrapped metals.

Flux de travail opérationnel:
1. Alimentation & Présélection: Runofpile slag is fed via loader or conveyor into a vibrating grizzly feeder, qui élimine les fractions fines (30mm) pour contourner le concasseur primaire, increasing system efficiency.
2. Concassage primaire: Oversize material is reduced by a heavyduty jaw crusher or impactor designed for high compressive strength feed.
3. Séparation des métaux & Concassage secondaire: The crushed product typically passes over an overhead magnetic separator to remove liberated ferrous scrap. The remaining material is further reduced by a cone crusher or secondary impactor to achieve the target grain size (par ex., 20mm).
4. Dimensionnement & Stockage: A final vibrating screen classifies the product, avec recyclage des matériaux surdimensionnés. Onspec material is conveyed to stockpile for sale as aggregate or for further processing.

Champ d'application: Idéal pour les aciéries intégrées, fonderies, chantiers de traitement des scories, and aggregate producers handling ferrous and nonferrous slags.

Limites: Not designed for primary mining of virgin rock or for processing materials with extreme moisture or clay content without preconditioning.

3. CARACTÉRISTIQUES PRINCIPALES

Mangeoire vibrante robuste pour grizzlis | Base technique: Highstrength eccentric shaft drive | Avantage opérationnel: Removes fines upfront, regulates feed to the primary crusher preventing chokefeeding | Impact sur le retour sur investissement: Reduces primary crusher load by up to 30%, lowering wear and energy consumption per ton processed.

AbrasionResistant Liner Packages | Base technique: Airhardening manganese steel or composite ceramic/metal alloys | Avantage opérationnel: Durée de vie du revêtement prolongée de 4060% compared to standard manganese in highabrasion zones | Impact sur le retour sur investissement: Decreases downtime for liner changes and reduces annual spare parts inventory cost.

Circuit de séparation magnétique intégré | Base technique: Overband selfcleaning magnets positioned at optimal discharge points | Avantage opérationnel: Continuously extracts liberated ferrous metal during crushing stages | Impact sur le retour sur investissement: Creates a direct revenue stream from scrap recovery and protects downstream conveyors and crushers from metal damage.

Graissage centralisé & Systèmes hydrauliques | Base technique: Automated lubrication points for bearings and hydraulic adjustment/tramp release systems | Avantage opérationnel: Ensures critical components are lubricated under all operating conditions; allows quick clearing of uncrushables | Impact sur le retour sur investissement: Empêche les défaillances catastrophiques des roulements (a major cause of downtime) and minimizes manual maintenance intervention time.

Intégration du système de suppression de poussière | Base technique: Réseaux de buses aux points de transfert connectés à l'alimentation en eau avec commande par solénoïde | Avantage opérationnel: Effectively controls dust emissions at source during crushing operations | Impact sur le retour sur investissement: Atténue les risques de non-conformité environnementale et réduit les coûts de main-d'œuvre d'entretien ménager.

Robust Structural Fabrication | Base technique: Stiffened frame design with heavyduty crawler or fixed plant support legs | Avantage opérationnel: Maintains alignment under continuous highvibration loads over years of operation | Impact sur le retour sur investissement: Eliminates costly structural repairs and prevents premature failure of mounted components due to frame flexing.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Solution standard de l'industrie | Notre solution pour une usine de broyage de scories | Avantage (% amélioration) |
| : | : | : | : |
| Disponibilité / Temps de disponibilité | 8085%, frequent jamming from tramp metal >8592%, hydraulic tramp release clears uncrushables in 8% augmenter |
| Durée de vie du revêtement au stade primaire (Acier au manganèse) ~40,000 MT throughput ~60,000 MT throughput >50% amélioration |
| Specific Power Consumption ~0.8 1.0 kWh/ton ~0.65 0.75 kWh/tonne >20% réduction |
| Metal Recovery Efficiency Manual picking postcrushing Inprocess magnetic separation at 2 stages Scrap recovery yield increased by 1525% |
| Dust Emission at Transfer Points Dry crushing with local extraction Wet suppression system at source PM10 emissions reduced by >90% |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 TPH à plus 300 Laitier traité TPH.
Exigences d'alimentation: La puissance totale installée varie généralement de 150 kW (pour 50 Usine TPH) à 450 kW (pour 300 Usine TPH), dépend de la configuration.
Spécifications matérielles: Primary crusher jaws/liners manufactured from premiumgrade Manganese Steel (1822%). Critical wear plates utilize AR400 steel. Structural frames fabricated from heavyduty ISMC/ISMB sections.
Dimensions physiques (Typique 150 Usine TPH): Longueur (~25m) x Largeur (~8 m) x Hauteur (~7m). Available in fixed skidmounted or semimobile trailer versions.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +50°C. Le système de suppression de poussière nécessite un approvisionnement en eau propre à 3040 psi; consumption approx. 50 liters per ton crushed.

6. SCÉNARIOS D'APPLICATION

Défi du parc à scories d'aciérie intégrée:

A major steel producer faced inconsistent feed from aged stockpiles causing daily chokeups in their existing crusher, limiting aggregate production to just one shift per day due to maintenance needs.

Solution:

Réalisation d'un projet clé en main Usine de concassage de scories featuring an extradeep crushing chamber jaw crusher with hydraulic toggle adjustment for quick CSS changes, paired with a powerful overhead magnet on the primary discharge belt.

Résultats:

Plant availability increased to three full shifts. Aggregate production rose by 210%. Recovered ferrous scrap generated sufficient revenue to cover the plant’s operating labor costs annually.

Copper Smelter Tailings Reprocessing Challenge:

A smelter sought to recover residual copper from old dump slag but found that conventional hammer mills created excessive fines (3mm), rendering gravity separation ineffective.

Solution:

A twostage Usine de concassage de scories using a jaw crusher followed by a cone crusher in closed circuit with a screen was deployed for controlled size reduction targeting 12mm+3mm.

Résultats:

The optimized grain size distribution improved recovery rates in the downstream jig plant by over 18%. The robust design handled the highly abrasive silicarich slag with liner life meeting projected targets.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Solutions are projectspecific but generally fall into three categories:
Standard SkidMounted Plant (50100 TPH): A costeffective entry point for lower volume processors.
Modular MediumCapacity Plant (100200 TPH): The most common configuration offering optimal balance of output and investment.
HighCapacity Fixed Stationary Plant (200300+ TPH): Designed for largescale producers requiring maximum uptime and automation.
Fonctionnalités facultatives: Vibrating feeder vs apron feeder; secondary cone vs impact crusher; automated metal detection system; advanced PLC control panels with remote monitoring capability; enceintes acoustiques.
Forfaits de services: Plans de garantie prolongée; contrats d'inspection annuels; guaranteed spare parts delivery schedules (par ex., 48hour critical parts availability).
Options de financement: Equipment leasing structures through partner financial institutions; milestonebased project payment plans for turnkey installations.

8. FAQ

1. Is your Slag Crusher Plant compatible with our existing conveyors and material handling infrastructure?
Our engineering team can design transfer heights and discharge points to match your current layout during the project specification phase.

2. Quel est le niveau de bruit de fonctionnement attendu?
With standard equipment enclosures, les mesures sur le terrain montrent généralement des niveaux inférieurs 85 dB(UN) at a distance of one meter from the machinery when processing dry slag.

3. How long does installation take?
For a skidmounted plant delivered preassembled on our frames, onsite commissioning can be completed within two weeks after foundation readiness upon arrival at your site

4.Pouvez-vous fournir des garanties de performance?
Yes we offer guaranteed minimum throughput capacity based on defined feed material characteristics as well as maximum power consumption per ton

5.Quelles sont les conditions de paiement habituelles?
For custom plants terms are generally structured as follows
30% advance payment
60% against dispatch
10% after successful commissioning

6.Do you offer training for our operators
Comprehensive training covering operation routine maintenance safety procedures troubleshooting is provided onsite during commissioning

7.How do you handle warranty claims
We maintain regional service hubs Warranty claims initiate through our service manager who coordinates diagnostics part dispatch if needed technician deployment if required