1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Managing slag byproduct is a persistent operational and financial drain. Êtes-vous confronté à ces défis communs?
Coûts d'élimination élevés: Les frais de mise en décharge des scories non traitées augmentent, érodant directement les marges des projets.
Traitement manuel inefficace: Reliance on manual breaking or basic machinery leads to low throughput, coûts de main d'œuvre élevés, and inconsistent output sizing.
Valeur du métal non récupéré: Valuable ferrous metal trapped within slag is lost to waste streams, representing a direct revenue leak.
Equipment Downtime: Standard crushers not built for abrasive slag suffer premature wear on liners and blow bars, causing frequent stoppages for maintenance.
Encombrement des sites & Logistique: Stockpiled slag consumes valuable space and complicates site logistics, hindering other operations.

What if your slag handling could transform from a cost center into a source of recovered material and improved site efficiency? The solution lies in purposeengineered processing equipment.

2. APERÇU DU PRODUIT

A White Label Slag Crusher Plant is a turnkey, unbranded processing system designed specifically for the size reduction and liberation of metals from metallurgical slag (haut fourneau, four à acier, etc.). The plant is provided as a complete package, ready for your branding and integration.

Flux de travail opérationnel:
1. Alimentation & Présélection: Raw slag is fed into a vibrating grizzly feeder to remove fine undersize material prior to crushing.
2. Réduction de la taille primaire: A robust jaw crusher or impact breaker performs the initial crushing, breaking down large slabs of slag.
3. Libération du métal & Séparation: The crushed material is conveyed to an electromagnetic separator which extracts liberated ferrous metal for recycling.
4. Concassage secondaire & Dimensionnement (Facultatif): A cone crusher or secondary impactor further processes the material to achieve precise final product specifications.
5. Stockage: Le nettoyé, sized aggregate is conveyed to a designated stockpile for use as a secondary raw material in construction or road base.

Champ d'application: Idéal pour les aciéries, fonderies, metal recycling yards, and independent processors handling ferrous slag byproducts.
Limites: Not designed for nonferrous slags without magnetic separation components or for primary rock mining applications with higher compressive strengths.

3. CARACTÉRISTIQUES PRINCIPALES

HEAVYDUTY FEEDER | Base technique: Reinforced grizzly bars with high stroke vibration motors | Avantage opérationnel: Poignées grandes, uneven slag slabs without bridging; removes fines to increase primary crusher efficiency | Impact sur le retour sur investissement: Réduit l'usure du broyeur jusqu'à 15% and improves overall system throughput.

ABRASIONRESISTANT CRUSHING CHAMBER | Base technique: Revêtements en acier au manganèse & wear parts with optimal nip angles | Avantage opérationnel: Withstands continuous abrasive impact, extending service intervals by 3050% over standard configurations | Impact sur le retour sur investissement: Lowers costperton for wear parts and reduces downtime for liner changes.

INTEGRATED MAGNETIC SEPARATOR | Base technique: Selfcleaning crossbelt electromagnet with adjustable height/intensity | Avantage opérationnel: Automatically extracts liberated ferrous metal continuously during operation | Impact sur le retour sur investissement: Captures 95%+ de métal récupérable, creating a new revenue stream from waste.

CENTRALIZED PLC CONTROL SYSTEM | Base technique: Automated process sequencing with fault diagnostics | Avantage opérationnel: Permet le contrôle par un seul opérateur de l'ensemble de l'usine; provides clear alerts for maintenance issues | Impact sur le retour sur investissement: Reduces labor requirements and prevents minor issues from causing major breakdowns.

MODULAR PLANT DESIGN | Base technique: Bolttogether subassemblies on heavyduty skid bases | Avantage opérationnel: Simplifies transportation and reduces onsite installation time and cost by an estimated 40% | Impact sur le retour sur investissement: Faster commissioning gets your return on investment started sooner.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Basic Crusher) | White Label Slag Crusher Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Taux de récupération des métaux | Manual picking or postcrush separation ~70% recovery rate. Integrated inline magnetic separation captures >95%. Up to ~35% more metal recovered |
| Durée de vie des pièces d'usure| Standard manganese in generic crushers lasts ~40k tons in slag duty.| Alliage optimisé & design yields ~60k tons per set.| ~50% longer operational life |
| Débit de tonnage| Discontinuous feeding due to bridging; inconsistent feed size.| Présélection & heavyduty feeder ensures steady, optimized feed to crusher.| Up to ~25% higher sustained throughput |
| OnSite Setup Time| Componentbased delivery requiring significant assembly.| Preassembled modules reduce field connection work.| Déploiement ~40 % plus rapide |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 50 à 250 tonnes par heure (TPH).
Exigences d'alimentation: Total installed power typically 150kW 400kW depending on configuration; 400V/50 Hz ou comme spécifié.
Spécifications matérielles: Constructed from S355JR structural steel; crushing chambers lined with Mn18Cr2 or equivalent highabrasion steel.
Dimensions physiques clés (Configuration typique): Trémie d'alimentation: 8m³; Ouverture d'alimentation du concasseur primaire: 750mm x 500 mm; Empreinte végétale (Lxl): environ. 25mx 7m.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; les connexions du système de suppression de poussière sont standard.

6. SCÉNARIOS D'APPLICATION

Steel Mill OnSite Processing | Défi: A midsized steel mill faced rising landfill costs for blast furnace slag and needed to clear storage yards. Manual processing was too slow. Solution: Implementation of a midrange white label slag crusher plant with magnetic separation at the yard perimeter. Résultats: Achieved processing of 120 TPH; eliminated landfill fees; recovered over $75k annually in scrap metal sales; created saleable aggregate.

Independent Recycling Contractor Expansion Challenge An aggregate recycler sought to diversify into industrial byproducts but required a costeffective entry solution without premium branding costs.Solution Acquisition of a base model white label plant allowing them to apply their own brand Result Enabled service contracts with two local foundries increased overall site revenue by an estimated increased asset utilization

Foundry Byproduct Management Challenge A foundry's cupola slag was being sold at minimal value as mixed waste containing recoverable metallics Solution Installation of a compact white label crushing and screening circuit focused primarily on metal liberation Result Metal recovery increased yield by concentrated aggregate product commanded higher market price improving margin on byproduct

7 CONSIDÉRATIONS COMMERCIALES

White label plants offer significant value by eliminating brand premiums Pricing is tiered based on capacity and automation level

Tier Basic Model Includes primary jaw crusher grizzly feeder magnetic separator basic belt conveyors manual controls Ideal for lower volume or entrylevel applications
Tier Pro Model Adds secondary impactor vibrating screen after magnet PLC control panel dust suppression system For operations requiring specific product sizing
Tier Custom HighCapacity Model Includes larger feeders dual crushing stages advanced screening multiple magnets full automation package For highvolume dedicated processing facilities

Optional Features Radial stacker conveyor additional screening decks metal baler press advanced dust collection
Service Packages are available separately including commissioning spare parts kits preventive maintenance plans extended warranty
Financing Options can be facilitated through equipment financing partners offering lease or loan structures typically ranging from months

8 FAQ

What feedstock size can the plant accept
The primary crusher is configured based on your typical slab size Common feed openings accept material up tomms in dimension

How pure is the recovered metal
Field data shows the integrated crossbelt magnet typically extracts ferrous material at purity facilitating direct sale to scrap yards without further processing

Are these plants suitable for portable skidmounted use
Yes core designs are skidmounted allowing relocation between sites with appropriate haulage equipment some models offer trailer mounting

What is the expected lead time from order to commissioning
For standard configurations lead time averages weeks factoring in manufacturing testing disassembly shipment reassembly onsite commissioning varies

Can the plant process other materials like construction demolition waste
While robust it is optimized for abrasive slags Minor configuration changes can adapt it C D waste but throughput may differ from dedicated C D equipment