1. ABERTURA ACIONADA POR PAINPOINT

Are you managing the significant cost and complexity of slag byproduct from your metallurgical operations? Tamanho de feed inconsistente, material abrasivo, and the need for precise final grading create persistent challenges for plant managers. Common issues include premature wear on crusher components leading to excessive maintenance downtime, inefficient processing that fails to liberate all valuable metals, and a lack of flexibility to handle varying slag types or production demands. This results in lost revenue from unrecovered material, high operational costs for parts and labor, and bottlenecks in your overall material handling circuit. Are you seeking a solution that delivers consistent throughput, maximizes metal recovery, and reduces your total cost of ownership? UM bespoke slag crusher plant is engineered to address these exact operational and financial pressures.

2. VISÃO GERAL DO PRODUTO

UM bespoke slag crusher plant is a customengineered stationary or semimobile crushing system designed specifically for the size reduction and liberation of metallurgical slag (alto-forno, aço, cobre, etc.). Unlike standard aggregate crushers, it is configured for extreme abrasion resistance and tailored to the specific chemical and physical properties of your slag stream.

Fluxo de Trabalho Operacional:
1. Recebimento Primário & Pré-triagem: Slag is fed via excavator or loader into a heavyduty vibrating grizzly feeder, que remove material fino (40milímetros) bypassing the primary crusher.
2. Redução de tamanho primário: Material de tamanho grande entra em um britador primário robusto (normalmente um tipo de mandíbula ou impacto) to break down large slabs and chunks.
3. Britagem Secundária & Libertação: O material é transportado para um britador secundário (muitas vezes um cone ou impactador) para redução adicional, optimally liberating encapsulated metal from the slag matrix.
4. Separação de Metais & Dimensionamento Final: Crushed product passes over magnetic separators (overband or drum) para extrair metal ferroso. Subsequent screening decks classify the crushed slag into precise commercial grades (por exemplo, 05milímetros, 520milímetros).

Escopo de aplicação & Limitações:
This plant is designed for processing cooled, solidified metallurgical slag. It is not suitable for molten slag or nonmetallic industrial byproducts without significant reengineering. Maximum feed size and final capacity are determined during the bespoke design phase based on clientspecific feedstock analysis.

3. RECURSOS PRINCIPAIS

Alimentador de avental para serviço pesado | Base Técnica: Overlapping manganese steel flights driven by rugged crawler tractors | Benefício Operacional: Handles direct tipping of large, abrasive slag pieces with minimal wear and consistent feed rate to the primary crusher | Impacto do ROI: Eliminates feeder damage common with standard plate feeders, reducing unplanned stoppages and replacement costs by an estimated 60%.

Primary Jaw Crusher with Wedge System | Base Técnica: Deep crushing chamber with steep nip angle and hydraulic toggle adjustment | Benefício Operacional: Effectively processes slabby slag with high compressive strength; hydraulic adjustment allows quick setting changes for varying feed or product requirements | Impacto do ROI: Increases availability through faster setting changes and provides up to 15% better throughput on abrasive materials versus standard designs.

HighStrength Liner Alloys | Base Técnica: Austenitic manganese steel with carbide additions or composite ceramic inserts in highwear zones | Benefício Operacional: Extends liner life in both primary and secondary crushing chambers exposed to highly abrasive slag | Impacto do ROI: Directly reduces consumable parts expenditure; dados de campo mostram um 40100% increase in liner life compared to standard manganese steel.

Circuito Integrado de Separação Magnética | Base Técnica: Strategic placement of selfcleaning overband magnets and drum magnets on transfer points postcrushing | Benefício Operacional: Maximizes recovery of liberated ferrous metal continuously during operation without manual intervention | Impacto do ROI: Captures additional revenue stream from scrap metal; improves final product purity for highervalue aggregate sales.

Controle PLC Centralizado & Sistema de monitoramento | Base Técnica: Programmable Logic Controller with HMI touchscreen providing realtime amp draws, temperaturas dos rolamentos, e totais de produção | Benefício Operacional: Gives operators immediate insight into plant health and performance, enabling predictive maintenance and quick diagnosis of faults | Impacto do ROI: Minimiza falhas catastróficas; testes da indústria demonstram um potencial 30% reduction in troubleshooting time.

Modular Skid or TrackMounted Design | Base Técnica: Plant sections built on heavyduty structural skids or mobile tracks | Benefício Operacional: Offers flexibility for future site relocation or phased expansion with reduced civil works cost and faster installation | Impacto do ROI: Lowers capital investment in permanent infrastructure by up to 25% and shortens commissioning time.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Planta agregada genérica) | Bespoke Slag Crusher Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Vida útil do forro (Primário)| Padrão 14% Aço manganês | Custom Alloy/Composite Liners | +40% para +100% |
| Taxa de recuperação de metal| Postcrushing magnetic separation only | Integrated multistage magnetic separation at optimal liberation points| +15% para +25% recuperação |
| Disponibilidade de planta| Reactive maintenance schedule; manual greasing points| PLC monitoring with predictive alerts; centralized autolubrication| +8% para +12% tempo de atividade |
| Tonelagem por kWh| Fixedspeed drives; nonoptimized flow| Loadresponsive VFDs on conveyors; optimized chamber designs| +5% para +10% eficiência |
| Tempo de reconfiguração| Welded structures; fixed layouts| Modular skids with flanged connections; adjustable crusher settings| 50% downtime for changes |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 50 TPH acima 400 TPH of inlet slag.
Tamanho da alimentação: Accepts slab feed up to 1000mm x 1500mm (subject to primary crusher selection).
Requisitos de energia: Total installed power typically between 250kW – 800kW based on configuration; supplied for 400V/50Hz or other regional standards.
Principais especificações de materiais: Primary frame – S355JR structural steel; Highwear hoppers/liners – Hardox 450/500 ou equivalente; Crusher jaws/mantles – Premium modified manganese steel.
Dimensões Físicas: Highly variable per design. A typical skidmounted primary section may be approx. C15m x L4m x A6m.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C com sistemas de lubrificação apropriados. Dust suppression spray systems are standard at transfer points.

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Mill Slag Processing Yard Challenge:

A major steel producer faced escalating landfill costs for aged blast furnace slag banks while losing revenue from unrecovered scrap metal within the piles.
Solução:
Implementation of a semimobile bespoke slag crusher plant featuring a primary jaw crusher followed by an impactor for cubical shaping.
Resultados:
A planta processou mais de 1.2 million tons of stockpiled slag annually into highvalue railway ballast aggregates while recovering an additional €180k/year in ferrous scrap metal previously landfilled.

Copper Smelter Byproduct Valorization Challenge:

A smelter needed consistent processing of granulated copper slag into fine sand substitute but struggled with variable hardness causing frequent blockages in their existing system.
Solução:
A bespoke twostage vertical shaft impactor (TODOS) plant was engineered specifically for granulated copper's abrasiveness.
Resultados:
Achieved consistent production of minus6mm sand meeting construction specifications at >95 TPH reliability while reducing specific wear costs by over €0.12 per ton processed compared to prior equipment.

7. CONSIDERAÇÕES COMERCIAIS

Níveis de preços: Investment varies significantly based on capacity automation level
Configuração básica (150 TPH): Includes primary/secondary crushing core modules basic screening magnetic separation
Configuração aprimorada (+20%) Adds automated lubrication advanced dust control system PLC control panel
Solução chave na mão (+3550%) Includes civil works design installation commissioning training

Recursos opcionais: Metal detector prior tertiary crushing module automated sampling system remote monitoring telemetry water recycling system

Pacotes de serviços: Annual inspection parts supply agreements full maintenance contracts operator training programs

Opções de financiamento: Equipment leasing capital expenditure financing through partner institutions payperton processing agreements can be structured

8.Perguntas frequentes

What analysis do you require design my bespoke slug crushеr plаnt?
We require representative sample(é) your slug fоr laboratory testing determine its compressive strength abrasiveness index bulk density chemical composition Accurate feed rate target product sizes are also critical

How does а bespokе plаnt improve my metаl recоvery rаte over а retrofit solution?
Thе key strategic placement оf magnetic separators immediately after each crushing stage where liberation occurs Our design ensures maximum exposure оf liberated metаl tо thе magnetic field аt thе correct material depth оn thе belt which retrofit solutions often compromise

What iѕ thе typicаl delivery аnd commissionіng timeline fоr such custom equipment?
Following detailed engineering approval lead times range frоm months fоr skid mounted plants Site commissioning including mechanical erection electrical connection process optimization typically requires weeks depending оn site readiness

Are spare parts readily available given thе custom nature оf thе equipment?
While thе layout iѕ custom core components (crushers screens motors drives) аrе selected frоm globally recognized OEMs ensuring parts availability Our supply agreement includes detailed bill оf materials аnd recommended local stockholding fоr critical wear items

Can thiѕ plаnt bе relocated іf my operаtions move?
Yes Thе modular skid design iѕ explicitly engineered fоr relocation Each major module can bе disconnected transported reassembled аt new site significantly preserving уour initial capital investment compared tо fixed foundation plants