Ce Marked Slag Crusher Plant Quote
1. ABERTURA ACIONADA POR PAINPOINT
Managing slag byproduct is a persistent operational bottleneck with tangible costs. Você está enfrentando esses desafios?
Alto tempo de inatividade para britadores primários: Uncrushed slag with oversized metal inclusions causes frequent jams in primary crushers, leading to hours of unplanned maintenance and lost processing time.
Manuseio ineficiente de materiais & Classificando: Manual or rudimentary separation of valuable scrap metal from aggregate is laborintensive, inconsistent, and represents a loss of recoverable revenue.
Downstream Equipment Damage: Unidentified tramp metal and uncrushable debris bypass initial processing, causing accelerated wear or catastrophic failure in conveyors, telas, e britadores secundários.
Inconsistent Feed Size for Processing: Variable slag feed results in an inconsistent product size, reducing the efficiency and quality control of your final aggregate or feedstock.
A questão central para os gerentes de fábrica é: como você pode transformar um fluxo de resíduos caro em um fluxo controlado, profitable material flow while protecting your core crushing circuit?
2. VISÃO GERAL DO PRODUTO
A CEMarked Slag Crusher Plant is a purposebuilt, stationary or semimobile processing system designed for the primary reduction and liberation of slag from steel mills, fundições, and metal production facilities. Its design prioritizes the handling of abrasive, heterogeneous material containing metallic inclusions.
Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: A escória do forno de escoamento é alimentada através de uma carregadeira em uma tremonha robusta, muitas vezes com uma seção parda para contornar material subdimensionado.
2. Primary Liberation Crushing: O triturador de núcleo (normalmente um tipo de mandíbula ou impacto) aggressively reduces the slag mass, breaking it apart to liberate embedded metallic components.
3. Separação de Metais & Extração: O material triturado passa por um separador magnético suspenso (suspended magnet or magnetic pulley), which automatically extracts ferrous scrap for recovery.
4. Dimensionamento & Estoque: The separated aggregate fraction is conveyed to a primary stockpile or directly to a secondary screening circuit for further grading.
Escopo de aplicação: Ideal para usinas siderúrgicas integradas, pátios autônomos de processamento de escória, and aggregate producers specializing in secondary materials. Best suited for ferrous slag (BOF, EAF). Performance on nonferrous slags requires specific configuration.
Limitações: Not a substitute for fine grinding or tertiary crushing circuits. Feed size is limited by the primary crusher opening. Optimal operation requires material with a manageable moisture content to prevent clogging.
3. RECURSOS PRINCIPAIS
Alimentador Grizzly para Serviço Pesado | Base Técnica: Pré-seleção & alimentação regulamentada | Benefício Operacional: Removes fines prior to crushing and ensures a consistent, controlled feed rate to the crusher chamber | Impacto do ROI: Aumenta o rendimento do britador em até 15% and reduces wear on crusher liners
Reinforced Jaw Crusher Chamber | Base Técnica: High manganese steel liners & ângulo de estreitamento otimizado | Benefício Operacional: Withstands extreme abrasion and shock loads from uncrushable metals; hydraulic toggle adjustment allows quick setting changes | Impacto do ROI: Reduces liner replacement frequency by ~30% versus standard configurations
Integrated Overband Magnetic Separator | Base Técnica: Permanent magnet or electromagnetic circuit mounted over discharge conveyor | Benefício Operacional: Automatically extracts liberated ferrous scrap continuously during operation without stopping the process flow | Impacto do ROI: Capturas 95%+ de metal recuperável, creating a direct revenue stream from waste
Lubrificação Centralizada & Sistema Hidráulico | Base Técnica: Singlepoint lubrication lines for key bearings and hydraulic controls for adjustment/clearing | Benefício Operacional: Permite segurança, routine maintenance in under 30 minutos; allows operators to clear blockages remotely | Impacto do ROI: Cuts planned maintenance time by half and minimizes personnel exposure to equipment internals
CE Certified Safety Guards & Plataformas de acesso | Base Técnica: Total conformidade com a Diretiva de Máquinas da UE 2006/42/EC | Benefício Operacional: Fornece segurança, compliant access for inspection and maintenance; interlocks prevent operation during servicing | Impacto do ROI: Mitigates risk of regulatory noncompliance fines and reduces workplace incident potential
4. VANTAGENS COMPETITIVAS
| Métrica de desempenho | Padrão da Indústria (Basic Crushing) | CEMarked Slag Crusher Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Taxa de recuperação de metal | Picking manual pós-britagem (~7080%) | Continuous automated extraction during process (>95%)| +20% Eficiência de recuperação |
| Crusher Downtime due to Tramp Metal| 812 hours per month for clearing/repair| Menor que 2 hours per month with hydraulic clearing| ~80% Reduction in Unplanned Stops |
| Liner Life in Abrasive Service| Aprox.. 60,000 toneladas por conjunto| Aprox.. 85,000 toneladas por conjunto (reinforced)| ~40% Longer Service Life |
| Process Consistency (Controle de alimentação)| Manual loader feeding (variável)| Alimentador pardo + regulated flow (consistente)| Throughput stability improved by ~25% |
5. ESPECIFICAÇÕES TÉCNICAS
Faixa de capacidade: Configurável de 50 para 400 toneladas por hora.
Opções do britador primário: Maldito Mandíbula (models from 750x500mm to 1200x1000mm) or Impact Crusher with hydraulic adjustment.
Requisitos de energia: Potência total instalada normalmente entre 90 kW 250 kW, depende da configuração (400V/50Hz standard).
Principais especificações de materiais:
Revestimentos do britador: AR400 / Hardox steel or premium manganese steel.
Correia transportadora: Minimum EP400/3 with abrasionresistant covers.
Quadro Estrutural: Heavyduty welded sections from S355JR steel.
Dimensões Físicas (Configuração típica): Approximate footprint of 20m L x 8m W x 7m H. Designed for flat concrete foundation.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 10°C a +45°C. Dust suppression spray bars are fitted as standard at transfer points.
6. CENÁRIOS DE APLICAÇÃO
Integrated Steel Mill – BOF Slag Processing | Desafio: A European mill faced daily downtime in its aggregate plant due to oversized slag chunks containing "skulls" jamming their existing crusher. Manual metal recovery was inefficient.| Solução: Installation of a CEMarked Slag Crusher Plant with a heavyduty jaw crusher and powerful overband magnet at the slag tipping point.| Resultados: Unplanned crusher stoppages were eliminated. The plant now recovers an additional €45,000 annually in ferrous scrap sales and produces consistent 150mm aggregate for internal roadbase use.
Contratante independente de processamento de escória | Desafio: A contractor needed to process varying stockpiles of EAF slag at multiple sites but required compliance with EU site safety regulations.| Solução: A semimobile skidmounted CEMarked Slag Crusher Plant was selected.| Resultados:The unit can be relocated between sites within days while maintaining full CE compliance at each location. Contractual penalties related to noncompliant equipment were avoided.
7. CONSIDERAÇÕES COMERCIAIS
Our CEMarked Slag Crusher Plants are offered in three primary tiers:
Planta de serviço padrão: For lowervolume operations (<100tph). Inclui britador de mandíbula central,ímã,e transportador de descarga básico.
Planta para serviços pesados: For highvolume steel mills (>200tph). Features reinforced impactor option,alimentador vibratório para ursos pardos,and multiple magnetic separation stages.
SemiMobile Skid Plant: For multisite contractors.All core components mounted on heavyduty skidsfor transportability.
Recursos opcionais incluem:
- Secondary screening unit
- Advanced dust suppression system
- Metal fragmentizer attachment
- Pacote telemático de monitoramento remoto
We offer comprehensive service packages including scheduled maintenance plans,lifetime technical support,and guaranteed parts availability within48 hoursfor critical components.Financing options include capital purchase,tailored leasing agreements,e aluguel de estruturas próprias.
8.Perguntas frequentes
Q1.Esta planta é compatível com nosso sistema de transporte existente?
A1.Field data shows integration is straightforward.The plant's discharge heightand conveyor speed are engineeredto match standard downstream systems.We require your existing specificationsfor confirmation.
Q2.What is the expected operational cost per tonne processed?
A2.Based on configured powerand typical wear part consumption,costs range between €0 .80and €1 .50per tonne.This includes power,lubrificantes,and liner wear but excludes labor.Scrap metal revenue typically offsetsa significant portionof this cost.
Q3.How does CE marking affect installation timelines?
A3.CE marking signifies all safetydocumentationis preassembled.This can reduce commissioning timeby approximately15%as no retrofittingof guardsor safety systemsis required.Compliance documentationis provided upfrontfor site authority review.
Q4.Can it handle wetor sticky slag?
A4.The standard configuration performs optimallywith material moisture content below10%.For higher moisture,a hydraulic jaw crushera combinedwith specific hopper designsare availableas options toprevent bridgingand clogging
Q5.What warrantyis providedon major components?
A5.We providea24monthwarrantyon structural componentsanda12monthwarrantyon mechanicaland electricalpartsagainst manufacturing defects.Wear parts(revestimentos do britador)are coveredunder aseparateperformancebased warrantyterm
Q6.Are operator trainingand manuals included?
A6.Comprehensive documentationincludingCE Declarationsof Conformityinstallation manualsand parts listsare standard.We provideonsite operational trainingfor your crewover two daysat commissioning
Q7.Do you offer performance guarantees?
A7.We contractually guaranteecapacity throughputwithin5%of specified ratingmetal recovery ratesabove95%for liberated ferrous materialand thatthe plantwill meetall declaredCE safety standards