Devis d'usine de concassage de scories

Vos défis de traitement des scories vous coûtent plus cher que vous ne le pensez

Every ton of unprocessed slag represents lost revenue and mounting disposal costs. Plant managers report that inefficient slag crushing operations lead to:

• Jusqu'à 18% material loss due to improper size reduction and contamination
• $12,000–$25,000 monthly in excess wear on downstream equipment from uncrushed slag fragments
• 3–5 unscheduled downtime events per quarter caused by blockages in undersized crushers
• 40% higher energy consumption when using generalpurpose crushers not designed for slag's abrasive properties
• Risques de non-conformité réglementaire from improper slag handling and dust generation

Are your current crushing solutions delivering the consistent 20mm output your recovery process requires? Can your equipment handle the 8–10 Mohs hardness of steel slag without weekly liner replacements?

Présentation du produit: The Slag Crusher Plant

UN usine de concassage de scories is a dedicated processing system engineered to reduce molten slag byproducts—from steel mills, fonderies, and incineration facilities—into reusable aggregates and recoverable metal fractions. This integrated solution combines primary crushing, séparation magnétique, and secondary screening in a closedloop configuration.

Flux de travail opérationnel

1. Réception des aliments: Hot or cooled slag (up to 600°C) enters the vibrating feeder with grizzly bars, removing oversized material >300mm
2. Concassage primaire: Hydraulic jaw crusher reduces slag to 100–150mm, with automatic gap adjustment for tramp metal protection
3. Séparation magnétique: Overband electromagnet extracts ferrous content (60–75% recovery rate) before secondary crushing
4. Concassage secondaire: Cone or impact crusher produces final product of 0–20mm or 0–40mm, depending on specification
5. Dépistage & Classification: Multideck vibrating screen separates into 0–5mm, 5–10mm, and 10–20mm fractions, with recirculation of oversize material

Portée et limites de l'application

Convient pour: Blast furnace slag, steel converter slag, laitier de ferroalliage, laitier de cuivre, and incinerator bottom ash. Effective for slag with moisture content up to 15%.

Limites: Not recommended for highly viscous, unquenched slag exceeding 800°C without cooling conveyor. Maximum feed size of 500mm. Requires dust suppression system for indoor installations.

Fonctionnalités principales

Conception de concasseur à mâchoires robuste | Base technique: Finite element analysisoptimized frame with manganese steel liners | Avantage opérationnel: Handles tramp metal without catastrophic failure, réduisant les temps d'arrêt imprévus de 60% | Impact sur le retour sur investissement: $8,000–$15,000 annual savings in repair costs and lost production

Hydraulic Gap Adjustment System | Base technique: Accumulatorbased hydraulic cylinders with pressure sensors | Avantage opérationnel: Operators adjust output size in under 2 minutes sans calage manuel | Impact sur le retour sur investissement: 12–15% improvement in product consistency, reducing recrushing cycles

DualStage Magnetic Separation | Base technique: Rareearth neodymium magnets with 12,000 Gauss field strength | Avantage opérationnel: Recovers 92–95% of ferrous content versus 70% with standard magnets | Impact sur le retour sur investissement: Additional $18–$25 per ton of recovered metal scrap

SelfCleaning Dust Control System | Base technique: Negative pressure collection with pulsejet filter bags | Avantage opérationnel: Maintains PM10 levels below 50 µg/m³, meeting EPA and OSHA standards | Impact sur le retour sur investissement: Avoids $5,000–$20,000 in annual regulatory fines

Modular SkidMounted Configuration | Base technique: Précâblé, prepiped modules on structural steel frames | Avantage opérationnel: Installation completed in 5–7 days versus 3–4 weeks for fixed plants | Impact sur le retour sur investissement: 70% reduction in site preparation costs

Entraînement à fréquence variable (VFD) on Main Motor | Base technique: Sensorless vector control adjusting RPM to feed load | Avantage opérationnel: Reduces energy consumption by 18–25% during partial load operation | Impact sur le retour sur investissement: $6,000–$12,000 annual electricity savings for a 200 Usine TPH

Capteurs de surveillance de l'usure | Base technique: Ultrasonic thickness gauges on crusher liners and chutes | Avantage opérationnel: Predictive maintenance alerts 48–72 hours before failure | Impact sur le retour sur investissement: Élimine 90% of unplanned liner changeouts

Avantages compétitifs

| Mesure de performances | Norme de l'industrie (General Crusher) | Solution d'usine de concassage de scories | Avantage (% Amélioration) |
|||||
| Throughput consistency (variation) | ±15% | ±5% | 67% amélioration |
| Liner lifespan (tonnes traitées) | 8,000–12,000 tons | 25,000–35,000 tons | 190% plus long |
| Ferrous recovery rate | 65–72% | 92–95% | 32% plus haut |
| Consommation d'énergie par tonne | 3.2–4.0 kWh/t | 2.1–2.6 kWh/t | 35% réduction |
| Temps de changement (taille du produit) | 45–60 minutes | 8–12 minutes | 80% plus rapide |
| Dust emission (PM10) | 120–180 µg/m³ | 35–50 µg/m³ | 72% inférieur |
| Temps moyen entre pannes | 180–240 hours | 600–800 hours | 200% plus long |

Spécifications techniques

| Paramètre | Model SCP150 | Model SCP250 | Model SCP400 |
|||||
| Capacité | 150 TPH | 250 TPH | 400 TPH |
| Taille de l'alimentation (maximum) | 400 mm | 500 mm | 600 mm |
| Gamme de tailles de produits | 0–20 mm / 0–40 mm | 0–20 mm / 0–40 mm | 0–20 mm / 0–40 mm |
| Concasseur primaire | 36x24 jaw crusher | 42x30 jaw crusher | 48x36 jaw crusher |
| Concasseur secondaire | 3ft cone crusher | 4.25ft cone crusher | 5.5ft cone crusher |
| Main motor power | 150 kW | 220 kW | 315 kW |
| Puissance totale installée | 280 kW | 410 kW | 580 kW |
| Séparateur magnétique | 1,200 mm belt width | 1,500 mm belt width | 1,800 mm belt width |
| Plateformes d'écran | 2 (4.8mx 1,8m) | 2 (6.0m x 2.0m) | 3 (6.0mx 2,4 m) |
| Poids opérationnel | 52 tonnes | 78 tonnes | 115 tonnes |
| Dimensions (LxlxH) | 22m x 4.5m x 5.2m | 28m x 5.2m x 5.8m | 34m x 6.0m x 6.5m |
| Température de fonctionnement | 10°C à 55°C | 10°C à 55°C | 10°C à 55°C |
| Spécifications matérielles | Acier au manganèse (1214% Mn) doublures, AR400 chutes | Acier au manganèse (1418% Mn) doublures, AR500 chutes | Acier au manganèse (1822% Mn) doublures, AR600 chutes |

Scénarios d'application



Traitement des scories d'aciérie | Défi: UN 2.5 MTPA integrated steel plant was stockpiling 180,000 tons annually of BOF slag, incurring $1.2M in disposal costs and losing $3.8M in recoverable metal value | Solution: Installé un 250 TPH slag crusher plant with dual magnetic separation and closedloop water washing system | Résultats: 94% ferrous recovery generating $3.2M annual scrap revenue; 85% of nonmetallic slag sold as road base aggregate at $8/ton; période de récupération de 14 mois

Foundry Sand Reclamation | Défi: A gray iron foundry producing 40,000 tons/year of castings generated 12,000 tons of slagsand mixture, avec 35% metal content locked in waste | Solution: Déployé un 150 TPH slag crusher plant with air classification and eddy current separation | Résultats: 91% récupération des métaux (3,800 tons/year) valued at $1.1M; reclaimed sand reused at 70% replacement rate, économie $240,000 annually in new sand purchases; landfill reduction of 8,500 tons/year

Incinerator Bottom Ash Processing | Défi: A municipal wastetoenergy facility needed to process 65,000 tons/year of bottom ash to meet EU aggregate standards for construction use | Solution: Coutume 200 TPH slag crusher plant with ferrous/nonferrous separation and wet screening | Résultats: Produit 48,000 tons of certified aggregate (0–32mm) for concrete block manufacturing; recovered 4,200 tons of ferrous and 1,100 tons of nonferrous metals; atteint 92% material utilization rate

Considérations commerciales

Niveaux de tarification des équipements

| Modèle | Fourchette de prix de base | Comprend | Délai de livraison typique |
|||||
| SCP150 (150 TPH) | $480,000 – $620,000 | Concasseurs, séparateur magnétique, écran, convoyeurs, Panneau de contrôle | 12–14 semaines |
| SCP250 (250 TPH) | $720,000 – $950,000 | Au-dessus de + dust collector, réglage hydraulique de l'écartement, VFD | 14–18 semaines |
| SCP400 (400 TPH) | $1,150,000 – $1,500,000 | Au-dessus de + dual magnetic separation, surveillance de l'usure, automation | 18–22 semaines |

Fonctionnalités facultatives

• Hot slag handling conveyor (up to 600°C): $45,000–85 000$
• Water quenching system: $120,000–200 000$
• Forfait de surveillance à distance (Intégration SCADA): $35,000–$55,000
• Garantie prolongée (3 années / 10,000 heures): 8–12% du coût de l’équipement
• Kit de pièces de rechange (doublures, ceintures, roulements): $28,000–65 000 $

Forfaits de services

| Emballer | Couverture | Coût annuel |
||||
| Basique | 2 preventive maintenance visits, assistance téléphonique | $18,000 |
| Standard | 4 Visites PM, 24heure de réponse, formation des opérateurs | $32,000 |
| Prime | 6 Visites PM, 12heure de réponse, technicien sur place, garanties de performance | $55,000 |

Options de financement

• Location de matériel: 36–Conditions de 60 mois avec $1 rachat, tarifs à partir de 4.5% AVR (qualified buyers)
• Paiement différé: 10% vers le bas, 90% à la mise en service (6month deferral)
• Financement basé sur la performance: Paiements liés à des jalons de débit (minimum 85% de capacité nominale)
• Programme d'échange: 15–25% credit for existing crushing equipment (subject to inspection)

FAQ

Q: Can the slag crusher plant handle both hot and cold slag in the same shift?
UN: Oui. The standard configuration accepts slag up to 600°C with a cooling conveyor option. For mixed feed, the hydraulic gap adjustment allows operators to compensate for thermal expansion differences. Field data shows less than 3% throughput variation when alternating between hot and cold feed.

Q: What is the typical power consumption per ton for your slag crusher plant?
UN: Independent testing at three steel mill installations shows average consumption of 2.3 kWh/ton for the SCP250 model producing 0–20mm product. This compares favorably to the industry average of 3.5–4.0 kWh/ton for generalpurpose crushers processing similar material.

Q: How does the plant handle the abrasive nature of slag without excessive wear?
UN: The plant uses manganese steel liners (12–22% Mn content depending on model) with a workhardening surface that increases hardness from 200 HB to 450 HB under impact. En plus, the wear monitoring sensors provide 48hour advance warning of liner replacement needs. Typical liner life is 25,000–35,000 tons versus 8,000–12,000 tons for standard crushers.

Q: What is the minimum site area required for installation?
UN: For the SCP150 model, a minimum area of 40m x 25m is required, y compris trémie d'alimentation, crusher units, convoyeurs, product stockpile area, et les routes d'accès. The modular design reduces footprint by 30% compared to conventional fixed plants.

Q: Can the plant be integrated with existing slag handling systems?
UN: Oui. The control system includes Modbus TCP/IP and Profibus interfaces for integration with plant SCADA. The feed conveyor can be configured to accept material from existing cooling pits, granulation systems, or stockpile reclaimers. Onsite integration typically requires 3–5 days of commissioning.

Q: What is the typical ROI period for a slag crusher plant investment?
UN: Basé sur 12 installations over the past 3 années, the average payback period is 14–18 months for steel mill applications and 18–24 months for foundry and incinerator operations. This is driven by metal recovery revenue ($18–$35/ton of scrap), aggregate sales ($6–$12/ton), and avoided disposal costs ($25–$50/ton).

Q: What warranty and aftersales support do you provide?
UN: Couvertures de garantie standard 12 mois ou 4,000 heures d'ouverture, selon la première éventualité. This includes defects in materials and workmanship. Extended warranty options cover 24 ou 36 mois. Service response times are guaranteed at 24 hours for Standard package and 12 hours for Premium package, avec 95% ontime performance recorded over the last 24 mois.