1. ABERTURA ACIONADA POR PAINPOINT

Managing slag from your steel, ferroalloy, or nonferrous metal production is a persistent operational bottleneck. Inefficient processing directly impacts your bottom line through high handling costs, lost revenue from unrecovered metallics, and unplanned maintenance downtime. Você está enfrentando esses desafios?
High Disposal Costs & Liability: Transporting and landfilling untreated slag consumes significant budget and creates longterm environmental liability.
Unrecovered Metal Loss: Ineffective crushing leaves valuable metallics locked in slag, representing direct revenue loss per ton processed.
Tempo de inatividade excessivo & Vestir: Standard crushers not built for abrasive slag suffer rapid wear part failure, causing frequent, costly production stops.
Inconsistent Output & Bottlenecks: An undersized or illconfigured crusher creates irregular feed size for downstream screening and sorting, limiting overall plant throughput.
Espaço & Restrições Logísticas: Bulky, multistage crushing setups require excessive floor space and complicate material flow within a confined plant layout.

A questão central para os gerentes de fábrica é esta: how can you transform slag from a cost center into a recoverable asset while ensuring relentless, lowmaintenance operation?

2. VISÃO GERAL DO PRODUTO

Our Commercial Slag Crusher Plant is a heavyduty, stationary processing system engineered specifically for the continuous reduction of aircooled or granulated metallurgical slag. It is designed to liberate encapsulated metal for maximum recovery and produce a consistently sized aggregate product for commercial sale.

Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: Runofplant slag is fed via loader or conveyor into an integrated grizzly or scalping screen to remove fine fractions and bypass noncrushable debris.
2. Redução de tamanho primário: Oversize material is directed into the core impactor or jaw crusher module, applying high inertia to fracture slabs and liberate metallic inclusions.
3. Separação de Metais & Descarga: Crushed material discharges onto a heavyduty discharge conveyor, typically passing over an overhead magnetic separator to extract liberated ferrous metal.
4. Britagem Secundária (Opcional): For specific aggregate specifications, a secondary cone crusher module can be incorporated for precise cubical shaping.

Escopo de aplicação: Designed for integrated steel plants, fundições, copper smelters, and ferroalloy producers processing blast furnace (BF) escória, basic oxygen furnace (BOF) escória, electric arc furnace (EAF) escória, and nonferrous slags.

Principais limitações: Not designed for primary rock mining applications or processing unsorted demolition debris with excessive tramp metal. Feed size must comply with crusher opening specifications.

3. RECURSOS PRINCIPAIS

HeavyDuty Rotor & Impact System | Base Técnica: Highinertia rotor with monolithic manganese hammers/bimetal blow bars | Benefício Operacional: Sustains high impact energy against abrasive slag with minimal wear rate; handles occasional tramp metal without catastrophic failure | Impacto do ROI: Reduces wear part change frequency by up to 40%, lowering direct parts cost and labor hours dedicated to maintenance.

Ajuste Hidráulico & Limpeza | Base Técnica: Integrated hydraulic cylinders for apron positioning and crusher housing opening | Benefício Operacional: Allows operators to adjust product gradation in minutes and clear blockages safely without manual entry into the crushing chamber | Impacto do ROI: Eliminates hours of dangerous manual labor per blockage event; enables quick optimization for varying feed materials.

AbrasionResistant Lining System | Base Técnica: Bolton wear liners made of AR400/500 steel in highwear zones | Benefício Operacional: Protects the crusher’s structural frame from abrasion, preserving its longterm integrity and preventing costly structural repairs | Impacto do ROI: Extends the service life of the main chassis by years, protegendo seu investimento de capital.

Integrated Grizzly Feeder | Base Técnica: Steppededge vibrating grizzly feeder with adjustable spacing | Benefício Operacional: Removes subsize material before crushing (increasing effective capacity) and evenly distributes feed across full rotor width for uniform wear | Impacto do ROI: Increases total plant throughput by preventing chokefeeding of fines; extends wear part life through even distribution.

Controle Baseado em PLC & Monitoramento | Base Técnica: Centralized control panel with PLC featuring amp draw monitoring, bearing temperature sensors, and vibration detection points | Benefício Operacional: Provides realtime operational data to prevent overload conditions; enables predictive maintenance scheduling based on actual load data | Impacto do ROI: Prevents major component failures; allows maintenance planning during scheduled stops.

Modular Base Frame Design | Base Técnica: Preassembled crusher module mounted on a unified heavyduty support frame | Benefício Operacional: Simplifies foundation requirements and reduces onsite assembly time during installation; permite reconfiguração ou realocação futura | Impacto do ROI: Cuts installation costs by approximately 25% and minimizes plant commissioning downtime.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Solução padrão da indústria | Our Commercial Slag Crusher Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Vida útil da peça (Barras de sopro/martelos) | Fundições de aço manganês | Proprietary BiMetal Alloy Castings / Ceramic Composite Liners Optional| +3550% vida operacional mais longa |
| Metal Liberation Efficiency (Ferrous Recovery) ~90% liberation rate postcrush >95% liberation rate postcrush +57% increase in recovered metal yield |
| Throughput Consistency Under Abrasive Feed ~15% capacity drop over 100 horário de funcionamento <8% capacity drop over 100 horário de funcionamento +47% more stable output |
| Unplanned Downtime Due to Blockages Average 812 hours per month Average 50% reduction in blockagerelated stops |
| Custo total de propriedade (5Year Estimate) Based on parts + trabalho + downtime Based on our field data analysis Estimated 2030% mais baixo |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 50 acabar 600 toneladas métricas por hora (TPH), depending on feed size and desired product specification.
Requisitos de energia: Primary drive motors from 150 kW para 450 kW; total plant power dependent on configuration (alimentadores, transportadores).
Feed Size Maximum: Up to 1000mm x 1200mm slab handling capability (dependente do modelo).
Faixa de tamanho do produto: Adjustable from 150mm down to 40mm in primary configuration; finer sizes achievable with secondary circuit.
Principais especificações de materiais: Mainframe fabrications from heavyduty steel plate; Rotor shaft forged alloy steel; Bearings rated for high shock loads; Wear components in premium manganese or chromium iron alloys.
Dimensões Físicas (Typical Primary Module): Approximately L12m x W4m x H5m. Foundation loads provided per project.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; dust suppression system connections standard.

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Plant – BOF Slag Processing

Challenge A major steel producer faced escalating landfill costs for BOF slag and needed to recover contained scrap metal more efficiently. Their existing jaw crusher suffered constant liner wear and poor metal liberation.
Solution Implementation of a highinertia impactortype Commercial Slag Crusher Plant with an integrated magnetic head pulley on the discharge conveyor.
Results Metal recovery increased by 6%. The consistent 80mm output improved downstream screening efficiency by 15%. Wear part costs decreased by an estimated $18,000 annually due to longer service intervals.

Ferrochrome Smelter – Lump Slag Aggregate Production

Challenge A smelter required a reliable method to process large lumps of aircooled ferrochrome slag into a saleable construction aggregate. Throughput was limited by frequent jamming in their old compressionstyle crusher.
Solution Installation of a grizzlyfed impact crusher plant with hydraulic adjustment and clearing capabilities specifically configured for highly abrasive ferrochrome slag.
Results The plant achieved a steady throughput of 180 TPH without blockages. The hydraulic system enabled quick product size adjustments between rail ballast and road base specifications. Aggregate sales now offset over onethird of the site’s raw material handling costs.

7. CONSIDERAÇÕES COMERCIAIS

Our Commercial Slag Crusher Plants are offered in three primary tiers:
1. Standard Duty Plant: For lower tonnage (<150 TPH) or intermittent use applications processing less abrasive slags like some nonferrous varieties.
2. HeavyDuty Plant: Our most common configuration for continuous operation in EAF/BOF steel mills at midrange capacities (150400 TPH), featuring standard abrasion packages.
3. UltraDuty Plant: Engineered for maximum abrasion resistance (>400 TPH) in severe applications like stainless steel or highly abrasive alloy slags, featuring premium wear materials throughout.

Optional features include secondary/tertiary crushing modules automated metal sorting systems advanced dust suppression packages extended remote monitoring service contracts

Financing options are available including capital lease operating lease project financing terms tailored to match your cash flow requirements

8.Perguntas frequentes

Q What are my foundation requirements?
A We provide detailed foundation drawings specific to your ordered model Our modular base frame design simplifies civil work but requires a solid reinforced concrete pad designed by your contractor based on our load data

Q How does this integrate with my existing conveyors screens?
A Our engineering team will review your current layout feed points discharge heights The crusher plant is designed with standard conveyor interfaces We can specify necessary chutes transfer points as part of the scope

Q What is the expected operational availability?
A When maintained according to our schedule field data shows operational availability exceeding92 excluding planned maintenance stops This is due primarilyto the robust designand predictive monitoring systems

Q Can you provide performance guarantees?
A Yes we offer guaranteed minimum throughput capacity based on agreed feed material specificationsand product size as well as maximum power consumption under load These are detailed in commercial proposals

Q What does the typical service package include?
A Our recommended package includes scheduled inspections remote monitoring support annual bearing grease analysisand guaranteed priority shipmentof criticalwear parts This structured approach maximizes uptime

Q How long does installation take?
A Fora standard heavy dutyplantwith preassembled modules onsite mechanical erection typically requires1014 dayswith an experienced crew Electrical connectionand commissioning add further time dependenton site readiness