1. ABERTURA ACIONADA POR PAINPOINT

Managing slag stockpiles presents persistent operational and financial challenges. Are you contending with inefficient manual breaking methods that bottleneck your material flow? Does inconsistent feed size from primary crushing reduce your downstream screening and separation efficiency, leading to valuable metal loss? Are you facing excessive wear on crusher components from abrasive slag, driving up maintenance costs and unplanned downtime? The costs of slow processing, high consumable expenses, and metal recovery inefficiency directly impact your site’s profitability. How can you transform this byproduct into a consistent, highvalue aggregate stream while controlling operational expenditure? The solution requires a purposeengineered system designed for the specific demands of slag reduction.

2. VISÃO GERAL DO PRODUTO

UM Planta de britagem de escória is a stationary or semimobile processing system engineered specifically for the size reduction of aircooled blast furnace (namorado) escória ou escória de aço. Its core function is to crush large slag lumps into precisely graded aggregates for use in construction, construção de estradas, or as a feedstock for further metal recovery processes.

Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: Slag is loaded via excavator or loader into a robust feed hopper, often with a grizzly section to bypass fine material.
2. Britagem Primária: A heavyduty jaw crusher or impact breaker reduces large lumps (often up to 1m+) para um tamanho gerenciável.
3. Transferir & Britagem Secundária: O material é transportado para um britador secundário (typically a cone crusher or impact crusher) for further refinement to the target product size.
4. Dimensionamento & Separação: Crushed material passes through vibrating screens to separate it into specified fractions (por exemplo, 05milímetros, 510milímetros, 1020milímetros). Magnetic separators are often integrated at this stage to extract remaining ferrous metal.
5. Estoque: Os agregados classificados são transportados para estoques designados para expedição.

Escopo de aplicação: Ideal para usinas siderúrgicas integradas, pátios autônomos de processamento de escória, e produtores agregados especializados em subprodutos industriais.
Limitações: Não projetado para escória fundida; feed material must be aircooled and solid. Performance is contingent on proper feed size control and the specific abrasiveness and composition of the source slag.

3. RECURSOS PRINCIPAIS

Configuração do britador para serviço pesado | Base Técnica: Manganese steel jaws/liners with optimized crushing chamber geometry | Benefício Operacional: Sustained high throughput of highly abrasive material with reduced risk of premature failure | Impacto do ROI: Lower costperton crushed via extended wear life and reduced frequency of liner changes.
Sistema Integrado de Recuperação de Metal | Base Técnica: Overband magnetic separators positioned at key discharge points | Benefício Operacional: Contínuo, automated extraction of residual ferrous metal from the aggregate stream | Impacto do ROI: Creates an additional revenue stream from recovered scrap metal while protecting downstream equipment from tramp metal damage.
Vibration Dampening Base Frame | Base Técnica: Reinforced steel frame with antivibration mounts for major components | Benefício Operacional: Minimizes structural stress and transmitted vibration, ensuring stable operation and reducing foundation requirements | Impacto do ROI: Lowers installation complexity and cost, enhances longterm structural integrity of the plant.
Lubrificação Centralizada & Pontos de Monitoramento | Base Técnica: Manifolded lubrication lines for all major bearing points | Benefício Operacional: Permite segurança, efficient routine maintenance without requiring access to multiple isolated points during operation | Impacto do ROI: Reduces lubrication time by up to 50%, promotes bearing health, and decreases unscheduled downtime.
Adjustable Discharge Setting System | Base Técnica: Hydraulic or mechanical adjustment on secondary/tertiary crushers | Benefício Operacional: Allows operators to quickly change final product sizing to meet different market specifications | Impacto do ROI: Enables rapid response to changing customer demands, maximizing plant utilization and sales opportunities.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Industry Standard Slag Processing | Nossa solução para planta de britagem de escória | Vantagem (% Melhoria) |
| : | : | : | : |
| Rendimento de tonelagem (Material abrasivo)| Variável, often declines with liner wear| Consistent output maintained via optimized wear part design & fluxo| Até 1520% more consistent yield over liner life |
| Eficiência de recuperação de metal| Singlestage magnetic separation, often manual cleaning| Multistage magnetic separation at optimal transfer points| Ferrous recovery rates improved by 2530% |
| Tempo de inatividade de manutenção (Agendado)| Dispersed lube points; manual setting adjustment| Centralized systems & hydraulic adjustment features| Routine service time reduced by approximately 40% |
| Consistência da forma do produto| Basic crushing circuits can produce flaky aggregates| Chamber optimization & crushing stage matching produces more cubical product| Improved cubicity index enhances aggregate value for premium applications |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 50 TPH acima 300 TPH, depending on feed size and required product grading.
Requisitos de energia: A potência total instalada normalmente varia de 150 kW para 600 kW, supplied by mains connection or onboard diesel generator set for semimobile units.
Especificações de materiais: Primary wear components (forros, impeller bars) manufactured from highchrome martensitic steel or premium manganese steel. Structural frames use heavyduty rolled steel sections.
Dimensões Físicas (Configuração típica): Footprint varies by capacity; um 150 TPH plant may require approximately 25m (eu) x 18m (C) x 12m (H).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Dust suppression systems are standard to maintain environmental compliance.

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Plant Slag Yard | Desafio: Inefficient primary breaking causing backlog; low recovery of valuable metallics from old slag dumps leading to lost revenue. | Solução: Deployment of a turnkey Slag Crusher Plant with highcapacity jaw crusher for primary reduction and two stages of magnetic separation. | Resultados: Processing rate increased to 180 TPH; recovered an average of 8 tons of ferrous metal per operating day; cleared legacy stockpile within projected timeline.

Commercial Aggregate Producer Specializing in Industrial Byproducts | Desafio: Existing plant struggled with extreme abrasiveness of steel slag, resulting in unsustainably high wear part costs and poor product shape limiting marketability.| Solução: Installation of a purposebuilt Slag Crusher Plant featuring specialized abrasionresistant liners and a cone crusher secondary stage for improved particle shape.| Resultados: Wear part lifecycle extended by over 60%; produced highquality cubical aggregate meeting road base specifications; opened access to highervalue construction contracts.

7. CONSIDERAÇÕES COMERCIAIS

Our Slag Crusher Plants are offered in three primary tiers:
Configuração padrão: A robust base plant covering primary crushing, basic screening/conveying, and singlestage magnetic separation.
Configuração de recuperação aprimorada: Adds secondary crushing for finer grading optimization and multistage magnetic separation drums/scanners.
Fully Modular/Mobile Configuration: Skidmounted or trailerbased units offering shorter installation times and relocation flexibility.

Optional features include automated dust suppression systems, advanced vibration monitoring sensors, pacotes de geração de energia a bordo, and custom conveyor lengths.

We provide comprehensive service packages ranging from annual inspection plans to fullturnkey operation & maintenance contracts. Financing options including leasing structures are available through our partners to facilitate capital expenditure planning.

8. Perguntas frequentes

1. Is your Slag Crusher Plant compatible with our existing conveyors and screening equipment?
Sim; our engineering team designs the transfer heights and discharge points based on your site layout survey data provided during quotation.

2. What is the expected operational impact on our power consumption?
Field data shows that an optimized plant design uses energy more efficiently per ton processed than piecemeal systems due to reduced recirculation loads.

3. How does pricing typically scale with capacity?
Pricing follows an economyofscale curve but is also influenced by specific requirements like level of metallurgical recovery needed or environmental enclosures.

4. Quais são os termos comerciais padrão oferecidos?
We typically offer FOB pricing exworks alongside CIF quotations for international buyers; payment terms are structured around project milestones such as FAT (Teste de aceitação de fábrica).

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