1. ABERTURA ACIONADA POR PAINPOINT

Managing slag is a critical but costly bottleneck. Você está enfrentando esses desafios operacionais persistentes?
Altos custos de abrasão: The extreme abrasiveness of slag rapidly wears down crusher components, levando a frequentes, unplanned maintenance stops and soaring spare parts expenditure.
Unpredictable Feed & Tempo de inatividade: Inconsistent slag feed size and occasional tramp metal cause blockages and damage, resulting in hours of lost processing time per incident.
Throughput Inefficiency: An underperforming crusher creates a backlog at the slag yard, delaying material recovery for resale or further processing and tying up capital in static inventory.
Pó & Environmental Control: Dry slag processing generates significant fugitive dust, creating health hazards, environmental compliance risks, and site cleanup costs.

Is your current solution equipped to handle the specific demands of slag? Can you reduce your costpertonne while increasing plant availability?

2. VISÃO GERAL DO PRODUTO

A CE Marked Slag Crusher Plant is a stationary or semimobile crushing system specifically engineered for the primary, secundário, or tertiary reduction of metallurgical slag (alto-forno, forno de aço). Its design prioritizes durability against abrasion and shock loads from uncrushable materials.

Fluxo de Trabalho Operacional:
1. Feed material is loaded via excavator or wheel loader into a heavyduty vibrating grizzly feeder.
2. The prescreener removes fine fractions and directs oversize slag to the core crusher—typically a robust jaw crusher for primary duty or an impact crusher for secondary applications.
3. The crushed product is conveyed to subsequent screening units for precise size classification.
4. Onboard magnetic separation can be integrated to recover residual metal, enhancing product purity and value.
5. Sized aggregate is stockpiled via radial or stacker conveyors for dispatch.

Escopo de aplicação: Processing blast furnace (BF) escória, siderurgia (BOF/EAF) escória, and nonferrous slags into valuable aggregate for construction, base rodoviária, or cement raw feed.

Limitações: Not designed for primary rock mining or processing of highly plastic or claybound materials. Maximum input size is constrained by the specific plant model’s primary crusher opening.

3. RECURSOS PRINCIPAIS

HeavyDuty Grizzly Feeder | Base Técnica: Highstrength steel grids with stepped grizzly bars | Benefício Operacional: Effectively scalps fines and reduces direct load on the primary crusher, while absorbing impact from large chunks | Impacto do ROI: Extends crusher liner life by up to 30% and improves overall system throughput efficiency.

AbrasionResistant Crusher Geometry | Base Técnica: Optimized crushing chamber design with reinforced wear plates & replaceable liners in highmanganese or alloy steel | Benefício Operacional: Maintains consistent product gradation over extended periods despite abrasive feed | Impacto do ROI: Reduces liner changeout frequency by an average of 25%, lowering labor costs and parts inventory.

Integrated Metal Trap & Release System | Base Técnica: Hydraulic or mechanical uncrushable relief mechanism coupled with permanent overband magnet | Benefício Operacional: Automatically rejects tramp metal to prevent catastrophic damage; magnet recovers valuable ferrous scrap | Impacto do ROI: Eliminates costly rotor or jaw damage repairs; recovered metal provides ancillary revenue stream.

Enclosed Conveying & Supressão de poeira | Base Técnica: Dusttight conveyor transfers with strategically placed spray nozzles or bag filter connections (opcional) | Benefício Operacional: Significantly contains dust at transfer points, ensuring a cleaner, safer site | Impacto do ROI: Reduces water consumption vs. manual spraying and minimizes risk of noncompliance with industrial air quality standards.

Sistema de controle PLC centralizado | Base Técnica: Programmable Logic Controller with touchscreen HMI for monitoring motor loads, conveyor speeds, e níveis de compartimento | Benefício Operacional: Enables singleoperator control of the entire circuit for optimized performance and quick fault diagnosis | Impacto do ROI: Lowers personnel requirements per shift and reduces mean time to repair (MTTR) by providing clear operational data.

CE Certified Safety & Guarding | Base Técnica: Full compliance with EU Machinery Directive (2006/42/CE) including emergency stops, mechanical locking devices, and mandatory guarding on all rotating parts | Benefício Operacional: Provides a verifiably safe working environment for maintenance and operations staff | Impacto do ROI: Mitigates risk of workplace accidents, associated downtime, and liability.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Typical Crusher Plant) | CE Marked Slag Crusher Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Liner Life in Slag Duty| Standard manganese liners lasting ~60k tonnes| Proprietary alloy/HD manganese liners in optimized geometry| +40% para +60% increased lifetime |
| Disponibilidade do sistema| ~85%, factoring in wear part changes & bloqueios| ~93%, due to quickwear change designs & tramp metal protection| +8 percentage points improvement |
| Tramp Metal Damage Events| 24 significant incidents per year requiring major intervention| 75% reduction in related downtime |
| Dust Emissions at Transfer Points| Often reliant on basic water sprays with variable results| Engineered containment with controlled suppression/filtration options| Até 90% reduction in ambient PM10 levels (sitedependent) |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 80 acabar 400 toneladas por hora (TPH), depending on feed size and required product gradation.
Requisitos de energia: Total installed power typically between 150 quilowatts – 450 kW. Plants are configured for standard industrial supplies (por exemplo, 400V/50Hz).
Opções do britador primário: Maldito Mandíbula (Feed opening up to 1200x800mm) or Horizontal Shaft Impact Crusher (Rotor diameter up to 1300mm).
Especificações de materiais: Critical wear components constructed from HB500+ abrasionresistant steel; frames from S355JR structural steel.
Dimensões Físicas: Modular design adaptable to layout; typical footprint range from 15m x 25m to 25m x 45m for full circuit including conveyors.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +40°C; electrical components rated IP54 minimum for dust/moisture protection.

6. CENÁRIOS DE APLICAÇÃO

Steel Mill Slag Processing Yard | Desafio: A European steel producer faced excessive downtime due to tramp metal damaging their existing crusher and poor product shape limiting aggregate sales value. Their manual dust control was insufficient.| Solução: Implementation of a CE Marked Slag Crushing Plant featuring an impact crusher with hydraulic overload protection, an aggressive magnetic separator, and a fully enclosed fines conveyor with bag filter.| Resultados: Tramp metalrelated stoppages were eliminated. The improved cubical product shape commanded a €2/tonne premium in the market. Dust emissions were brought within strict local limits without manual watering.

Independent Aggregate Producer Recycling Landfilled Slag | Desafio: An operator processing historic landfill slag needed extreme durability against highly variable feed material containing rebar chunks and dirt clods.| Solução: A heavyduty jaw crusherbased CE Marked plant was selected for its robust frame design integrated prescreening grizzly feeder automatic metal release system.| Results The plant achieved consistent throughput of challenging material Spare part consumption decreased by an estimated compared to their previous mobile unit allowing profitable processing of previously uneconomic stockpiles

Cement Plant Raw Feed Preparation Challenge A cement manufacturer sought reliable precrushing of granulated blast furnace slag as SCM supplementary cementitious material but required very low iron contamination Solution Installation of twostage crushing circuit jaw cone with powerful magnetic separation after each stage Results Iron content in final crushed slag was reduced ensuring optimal performance as SCM while recovered scrap provided additional revenue Plant availability exceeded

7 CONSIDERAÇÕES COMERCIAIS

Pricing tiers are primarily defined by capacity throughput robustness

• Base Tier Standard Duty Plants TPH range Ideal for consistent lowerabrasion BF granulated slag
• Mid Tier HeavyDuty Plants TPH range Includes enhanced wear packages larger magnets ideal mixed BFEAF slags
• Premium Tier Custom HighAvailability Plants TPH Fully enclosed circuits advanced automation redundant systems

Optional Features Hydraulic adjustment systems dust filtration modules sound attenuation enclosures remote monitoring telematics packages winterization kits

Service Packages Extended warranty plans scheduled maintenance contracts liner changeout service bulk spare parts agreements

Financing Options Available capital equipment leasing structures operating lease agreements tailored support project financing models

8 Perguntas frequentes

What does CE Marking mean specifically this plant
CE Marking confirms this plant meets all essential health safety requirements EU Machinery Directive This includes verified documentation risk assessment technical file conformity procedures It mandatory legal market within European Economic Area provides clear compliance framework your safety audits

How does this plant handle wet sticky slag
While designed primarily dry freeflowing material optional features include heated chutes vibratory dischargers specific conveyor types mitigate adhesion For consistently highmoisture feeds consultation required determine optimal pretreatment screening configuration

What ongoing operational training provided
Comprehensive handover includes minimum two days onsite training operations maintenance teams covering daily checks troubleshooting safety procedures Detailed operation maintenance manuals digital formats also supplied Optional extended training available

Can existing conveyors screening units integrated new crushing island
Yes modular design allows integration certain existing infrastructure Site survey engineering review required confirm compatibility feed rates transfer heights electrical controls ensure optimal system performance

What typical lead time supply installation
Lead times vary configuration complexity Standard plant designs typically available within weeks exworks following order Custom solutions may require months Installation commissioning supervised our engineers typically requires weeks depending site readiness