1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Vous gérez une aciérie ou un chantier de transformation de scories et faites face à des goulots d'étranglement persistants dans votre chaîne de valorisation matière? The challenges with traditional slag handling are quantifiable and costly. Inconsistent feed size jams crushers, causing unplanned downtime that costs thousands per hour in lost production and labor. Abrasive slag components rapidly wear out standard crushing chambers, conduisant à de fréquents, expensive liner replacements and parts inventory burdens. En outre, inefficient separation results in valuable metallic content being lost to waste stockpiles, directly impacting your revenue recovery. Dust generation creates environmental and health compliance issues, while inflexible equipment cannot adapt to varying slag types or production demands.

La question centrale pour les directeurs d’usine est claire: comment pouvez-vous obtenir un, highvolume slag processing with lower operating costs and maximized metal yield? The answer requires a purposeengineered system, not just a standard crusher.

2. APERÇU DU PRODUIT

UN Usine de concassage de scories is a stationary or semimobile integrated processing system designed specifically for the size reduction and liberation of metallic content from steel slag, laitier de haut fourneau, and similar industrial byproducts. Il se transforme brut, lump slag into a graded, marketable aggregate while recovering ferrous metal for recycling.

Flux de travail opérationnel:
1. Concassage primaire & Dépistage: Gros morceaux de scories (jusqu'à 1000mm) are reduced by a primary jaw crusher. A preliminary screen removes fine material.
2. Séparation magnétique (Primaire): A suspended magnet over the conveyor extracts the majority of liberated ferrous metal postprimary crushing.
3. Concassage secondaire: A cone crusher or impactor further reduces the material to achieve optimal liberation of embedded metal.
4. Projection finale & Séparation: Material is classified into precise aggregate sizes (par ex., 05mm, 510mm, 1020mm). A second drum magnet ensures final metal recovery.
5. Stockage: Clean aggregate is conveyed to stockpiles; recovered metal is collected for sale or reuse.

Champ d'application: Integrated steel plants, chantiers de traitement de scories autonomes, mining operations handling abrasive materials.
Limites: Not designed for highly corrosive chemical slags or as a primary ore processing plant without significant configuration changes.

3. CARACTÉRISTIQUES PRINCIPALES

Alimentateur vibrant robuste | Base technique: Grizzly section with adjustable spacing | Avantage opérationnel: Removes subgrade fines and prevents primary crusher overload | Impact sur le retour sur investissement: Réduit l'usure du broyeur jusqu'à 15% and improves overall throughput stability.

Jaw Crusher with Manganese Steel Jaws | Base technique: High compression crushing with optimized nip angle | Avantage opérationnel: Effectively processes large, irregular slag lumps with high compressive strength | Impact sur le retour sur investissement: Les données de terrain montrent un 2030% longer service life compared to standard jaws in abrasive applications.

Electromagnetic Suspended Magnet | Base technique: Deep magnetic field penetration across full conveyor width | Avantage opérationnel: Recovers large tramp metal avant étapes de concassage secondaire | Impact sur le retour sur investissement: Protects downstream equipment from damage and captures highvalue scrap early in the process.

Liner Protection System (Cone/Impactor) | Base technique: Hydraulic adjustment and overload relief cylinders | Avantage opérationnel: Allows quick clearing of uncrushables and protects major components from catastrophic failure | Impact sur le retour sur investissement: Minimizes risk of costly repairs and reduces mean time to repair (MTTR) by hours.

Transport fermé & Dust Suppression Points | Base technique: Sealed transfer points with strategically placed spray nozzles | Avantage opérationnel: Controls airborne particulate at critical generation points | Impact sur le retour sur investissement: Mitigates environmental noncompliance risks and reduces site cleanup costs.

Système de contrôle PLC centralisé | Base technique: Automated sequencing with fault annunciation | Avantage opérationnel: Enables smooth plant startup/shutdown and provides operators with clear diagnostic information | Impact sur le retour sur investissement: Lowers operator error potential and simplifies troubleshooting.

Conception de patins modulaires (Facultatif) | Base technique: Preassembled structural frames for key modules | Avantage opérationnel: Reduces civil works cost and accelerates onsite installation time by an estimated 30% | Impact sur le retour sur investissement: Faster commissioning leads to earlier production revenue.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Slag Crusher Plant Solution | Avantage (% amélioration) |
|||||
| Taux de récupération des métaux | ~9092% | Jusqu'à 9698% | +68% Rendement |
| Durée de vie du revêtement (Étape primaire) | 80,000 100,000 MT processed | 120,000 150,000 MT processed | +4050% Durabilité |
| Disponibilité du temps de disponibilité du système 95% 97%+ +2% Disponibilité |
| Specific Power Consumption Baseline 1015% reduction through optimized drive systems 1015% Économies d'énergie |
| Dust Emission at Transfer Points Often requires addon bag filters Meets standards via integrated suppression Lower Capex on Dedicated Filtration |

Based on scheduled maintenance adherence.

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 TPH à plus 300 TPH.
Taille de l'alimentation: Accepte les scories en morceaux jusqu'à 1 000 mm de longueur de bord.
Exigences d'alimentation: Total connected load typically between 250kW 800kW depending on configuration; fourni pour 415V/3Phase/50Hz ou comme spécifié.
Spécifications matérielles: Primary wear parts (doublures, mâchoires) manufactured from Grade III Manganese Steel or equivalent AR plate; structural frames from heavyduty ISMC/ISMB sections.
Dimensions physiques: Varie selon la capacité; une norme 150 TPH plant footprint is approximately 35m (L) x 22m (W) x 15m (H).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 10°C à +45°C; dust and weather protection standard for outdoor installation.

6. SCÉNARIOS D'APPLICATION

Integrated Steel Plant Slag Yard Retrofit

Défi:
A major steel producer faced frequent breakdowns in their aging twostage crushing setup. La récupération des métaux était inefficace (~88%), leading to significant value loss in aggregate stockpiles. Temps d'arrêt dépassé 15 heures par mois.
Solution:
Implementation of a turnkey Slag Crusher Plant featuring a robust grizzly feeder, deepfield magnetic separators at two stages, and an automated cone crusher for secondary reduction.
Résultats:
La récupération des métaux a augmenté à plus 96%. Disponibilité du système atteinte >97%, reducing monthly downtime to under <5 heures. The recovered additional metal paid for the plant's operational costs within eight months.

Entrepreneur indépendant en traitement des scories

Défi:
A contractor needed mobile flexibility but required higher volume than portable crushers offered. Their challenge was inconsistent feed material from multiple small steel mills.
Solution:
A semimobile Slag Crusher Plant built on modular skids with quickdisconnect electrical/utility connections was deployed.
Résultats:
The plant could be relocated between sites within one week using conventional heavy transport. This flexibility allowed the contractor to service multiple clients without capital duplication while maintaining highvolume processing efficiency above >120 TPH consistently across varied feed materials.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Capital cost varies significantly based on capacity and automation level.
Niveau d'entrée: Manual/semiautomated plants up to ~75 TPH focus on core functionality.
Standard: Usines entièrement automatisées (~75200 TPH), including PLC control dust suppression represent the most common investment range
HauteCapacité: Customengineered systems (>200 TPH) often include advanced monitoring systems like liner wear sensors

Fonctionnalités facultatives & Mises à niveau: Vibrating screen decks for additional product fractions; metal baler/shear for scrap processing; systèmes de lubrification automatisés; remote monitoring via SCADA

Forfaits de services: Annual Maintenance Contracts (AMC), guaranteed spare parts supply agreements are available

Options de financement: Equipment leasing structures are commonly offered through partner financial institutions

8.FAQ

1.Q:What if our incoming slag composition varies significantly?
UN:The design incorporates adjustable crusher settings variable speed feeders allowing operators finetune throughput product size based realtime feed characteristics ensuring consistent output quality

2.Q:Quelles sont les exigences d'installation typiques?
UN:A level prepared base adequate electrical supply water connection dust suppression essential Detailed foundation layout drawings comprehensive utility specifications provided prior delivery facilitate smooth site preparation

3.Q:What ongoing maintenance should we expect?
A.Primary maintenance involves regular inspection replacement wear parts like crusher liners conveyor belts spray nozzles Scheduled lubrication critical bearings drives Welldesigned plant provides easy safe access all service points reduce labor time

4.Q.How does this integrate with our existing material handling equipment?
A.Plants are engineered accept feed from your current loaders conveyors Output conveyors can be positioned suit your existing stockpiling loading arrangements Control systems can often interface with broader site networks

5.Q.What warranty support do you provide?
A.A standard warranty covers manufacturing defects major components typically months extended warranties available purchase Comprehensive documentation includes operation manuals parts lists recommended maintenance schedules ensure your team fully supported