1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Managing slag byproduct is a persistent operational bottleneck with direct cost implications. Êtes-vous confronté à ces défis?
Coûts d'élimination élevés & Responsabilité: Les frais de mise en décharge des scories non traitées augmentent, et la surveillance réglementaire sur le stockage s'intensifie, creating both financial and environmental liability.
Récupération de matériaux inefficace: Valuable metallic content trapped within slag represents lost revenue and undermines raw material efficiency.
Downstream Processing Issues: Inconsistent, oversized slag material jams conveyors, damages equipment, and creates bottlenecks in your material handling circuit.
Multiple Equipment Dependency: Relying on separate, nonintegrated units for primary crushing, dépistage, and metal separation drives up capital costs and complicates maintenance.
Contractual Inflexibility: Sourcing a standard crusher often means adapting your process to the machine, not the other way around.

What if your slag handling could be transformed from a cost center into a controlled recovery operation? The solution lies in a purposeengineered system designed for this specific duty.

2. APERÇU DU PRODUIT

A White Label Slag Crusher Plant is a complete, turnkey processing system manufactured under contract to your specifications and branded for your company. It is engineered to reduce slag from furnaces, ladles, or stockpiles into a precisely graded aggregate while maximizing ferrous metal recovery.

Flux de travail opérationnel:
1. Alimentation & Présélection: Slag is fed via loader or conveyor; an initial grizzly screen removes fine fractions to bypass the crusher, augmentation du débit.
2. Réduction de la taille primaire: A robust crusher (généralement une mâchoire ou un impacteur) réduit les gros morceaux de scories à une taille gérable, libérer le métal incrusté.
3. Séparation des métaux & Récupération: Liberated metal is extracted via overhead magnetic separators positioned over discharge conveyors.
4. Dimensionnement final & Stockage: Crushed material passes through a vibrating screen to ensure product specification; sized aggregate is conveyed to stockpiles.

Champ d'application: Idéal pour les aciéries, fonderies, fonderies de métaux, and recycling facilities processing blast furnace (petit ami) scories, laitier de fourneau d'acier, or nonferrous slags with recoverable metal content.

Limites: Not designed for primary rock mining or extremely abrasive natural aggregates without specific configuration. Feed size and hardness parameters must be defined during engineering.

3. CARACTÉRISTIQUES PRINCIPALES

Conception de concasseur robuste | Base technique: Highchrome wear parts & reinforced rotor/body | Avantage opérationnel: Withstands extreme abrasion and occasional tramp metal with reduced wear rates | Impact sur le retour sur investissement: Extends component service life by 3050%, lowering costpertonne for wear parts

Circuit de séparation magnétique intégré | Base technique: Aimants à bande croisée autonettoyants aux points de décharge stratégiques | Avantage opérationnel: Automatically extracts liberated ferrous metal continuously without manual intervention | Impact sur le retour sur investissement: Récupère 95%+ de métal libre, converting waste to direct revenue stream

Système de contrôle basé sur PLC | Base technique: Centralized automation with fault diagnostics and process interlocks | Avantage opérationnel: Permet le contrôle par un seul opérateur de l'ensemble de l'usine; prevents jams and equipment damage | Impact sur le retour sur investissement: Reduces labor requirements and minimizes unplanned downtime due to operational errors

Modular Skid/Base Frame Construction | Base technique: Preassembled structural modules with integrated walkways and ladders | Avantage opérationnel: Significantly reduces site installation time and civil work costs | Impact sur le retour sur investissement: Réduit le temps d'installation jusqu'à 40%, accelerating timetooperational status

Système de suppression de poussière | Base technique: Strategically placed nozzles creating a micronlevel water curtain | Avantage opérationnel: Effectively controls dust at feed and transfer points, ensuring EPA compliance | Impact sur le retour sur investissement: Eliminates potential regulatory fines and creates a safer operator environment

Customizable Output Grading | Base technique: Interchangeable screen meshes in a highfrequency vibrating screen | Avantage opérationnel: Produce multiple aggregate specifications (par ex., 20mm, 40mm) from the same feed stock | Impact sur le retour sur investissement: Allows product diversification to meet different market demands or internal use cases.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Usine de concassage générique) | White Label Slag Crusher Plant Solution | Avantage |
| : | : | : | : |
| Taux de récupération des métaux (%)| 7080% (dependent on manual picking) | 95%+ (via integrated magnetic separation) | +1525% |
| Durée de vie des pièces d'usure (Heures) | ~500600 (standard manganese steel) | ~800900 (alliages à haute teneur en chrome) | +4050% |
| Installation & Temps de mise en service (Semaines) | 68 semaines (field assembly required) | 34 semaines (conception de patin modulaire) | 50% |
| Disponibilité du système (%)| ~85% (multiple component sources)| >92% (compatibilité technique) |>7% amélioration |
| Coût total de possession (5Année Estimation)| Plus haut (frequent part changes, lower recovery)| Inférieur (optimized wear life, high recovery)| Significant reduction |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 10 TPH à plus 150 TPH.
Taille d'alimentation maximale: Up to 800mm lump slag.
Exigences d'alimentation: Plant total dependent on configuration; typical range 150kW 450kW. Designed for 415V/3Phase/50Hz or clientspecified supply.
Crusher Core Options: Concasseur à mâchoires robuste (for high compression strength slag) or impact crusher with hydraulic assist (for better shaping & libération).
Spécifications matérielles: Crusher liners in AR400 or higher; chutes and wear plates in minimum 10mm abrasionresistant steel; structural frames in IS2062.
Dimensions physiques: Modular design variable; exemple pour un 50 TPH plant footprint approx. 20m L x 8m W x 7m H.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 10°C à +45°C; dust protection standard to IP55.

6. SCÉNARIOS D'APPLICATION

Integrated Steel Plant – Blast Furnace Slag

Défi: A major mill faced rising landfill costs for BF slag and needed to create saleable aggregate for cement production while recovering residual iron.
Solution: Implementation of a configured white label plant with heavyduty jaw crusher and twostage magnetic separation.
Résultats: Achieved consistent 25mm aggregate product meeting SCM specifications; recovered over 8 tonnes of metallics per day for recycling back into BOF; landfill diversion reached 98%.

Ferroalloy Smelter – Silicomanganese Slag

Défi: Abrasive SiMn slag was causing excessive wear on generic crushing equipment (<200 hours on hammers), creating high operating costs and unreliable supply of construction filler material.
Solution: Deployment of an impact crusherbased white label plant featuring specialized tungsten carbide tipped wear components.
Résultats: Wear part lifetime increased to over 650 heures; plant availability exceeded 90%; produced filler material met road subbase specifications consistently.

7. CONSIDÉRATIONS COMMERCIALES

White label manufacturing provides significant commercial flexibility:
Niveaux de tarification: Based on capacity and complexity – Basic Crushing Circuit → Crushing + Screening Module → Full Circuit with Metal Recovery & Automation.
Fonctionnalités facultatives / Mises à niveau: Dust encapsulation systems vs. suppression; advanced metal detectors; systèmes de lubrification automatisés; télématique de surveillance à distance.
Forfaits de services: Tiered offerings from basic documentation packs to comprehensive annual maintenance contracts with guaranteed response times and spare part holding agreements.
Options de financement: Through partner institutions – available as outright purchase, leasetoown agreements tailored to cash flow cycles typical in metallurgical industries.

8. FAQ

1. Q1 Can this plant be integrated with our existing material handling equipment?
Oui. As contract manufacturers we engineer transfer heights conveyor widths drive capacities control signals interfaces etc specifically match your upstream feeding downstream stacking systems

2 Q2 Quel est l'impact opérationnel attendu sur nos effectifs actuels?
Field data shows these automated plants typically require one trained operator per shift plus routine maintenance crew attention reducing reliance multiple manual laborers sorting feeding

3 Q3 How does the white label model affect lead time compared buying standard OEM model?
The contractual manufacturing process often reduces lead time because production scheduled dedicated slot based your approved drawings avoiding queue standard model production lines Engineering phase however remains critical path

4 Q4 Les garanties de performance sont-elles fournies?
Yes performance guarantees covering throughput final product grading metal recovery rate are stipulated contract based agreed feed characteristics These validated during factory acceptance testing FAT site commissioning

5 Q5 What are the key commercial terms regarding payment intellectual property?
Standard terms involve staged payments linked design approval manufacturing milestones shipment Typically all design drawings IP related your specific configuration remain your property manufacturer retains rights base engineering designs