1. ABERTURA ACIONADA POR PAINPOINT

A gestão da escória é um gargalo persistente com custos ocultos significativos. Você está enfrentando esses desafios operacionais?
Baixo rendimento & Alto tempo de inatividade: A britagem primária ineficiente cria um atraso, stalling downstream processing and idling material handling crews.
Abrasão excessiva & Custos de manutenção: Standard crushers wear rapidly when processing highly abrasive slag, levando a trocas freqüentes de revestimento, high spare parts consumption, and unpredictable maintenance budgets.
Redução de tamanho não confiável: Inconsistent feed size and composition result in poor fragmentation, causing recirculation loads that strain crushers and reduce overall plant efficiency by 1525%.
Alta Complexidade Operacional: Equipment requiring constant adjustment and monitoring increases labor intensity and the potential for unplanned stoppages.

A questão central para os gerentes de fábrica é esta: how can you transform slag from a costly byproduct into a efficiently processed, revenuegenerating aggregate without compromising your primary production line?

2. VISÃO GERAL DO PRODUTO

Our HighQuality Slag Crusher Plant is a heavyduty, stationary or semimobile processing system engineered specifically for the rigorous demands of ferrous and nonferrous slag reduction. It is designed to function as the primary size reduction node in your slag valorization circuit.

Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: Runoffurnace slag is fed via dump truck or loader onto a robust grizzly feeder, que remove frações finas (50milímetros) para contornar o britador, aumentando a capacidade efetiva.
2. Britagem Primária: Oversize material is directed into the core jaw crusher, where its high inertia and optimized kinematics fracture large slabs (até 1200 mm) em pedaços gerenciáveis.
3. Descarga & Transporte: Crushed material is discharged onto a heavyduty belt conveyor system for transport to secondary screening or stockpiling.

Escopo de aplicação: Ideal para siderúrgicas integradas, fundições de cobre, plantas de ferroligas, e pátios autônomos de processamento de escória que lidam com altos-fornos (BFS) ou escória de aço.
Limitações: Not designed for raw ore primary crushing or processing materials with extreme soil or clay contamination without preprocessing.

3. RECURSOS PRINCIPAIS

Triturador de mandíbula para serviço pesado | Base Técnica: Optimized nip angle and reinforced manganese steel castings | Benefício Operacional: Sustained high throughput on abrasive materials with less wearinduced chamber deformation | Impacto do ROI: Prolonga a vida útil do liner em até 40%, reducing direct spare parts cost and changeout downtime.

Alimentador Grizzly Integrado | Base Técnica: Barras grizzly escalonadas com espaçamento ajustável | Benefício Operacional: Remove finos antes da britagem, preventing chamber packing and maximizing throughput of oversize material | Impacto do ROI: Aumenta a capacidade efetiva do britador em 2030%, improving total circuit efficiency.

Sistema de automação baseado em PLC | Base Técnica: Controle centralizado com gerenciamento de carga e diagnóstico de falhas | Benefício Operacional: Permite a supervisão de um único operador, otimiza o consumo de energia, and provides early warning for maintenance events | Impacto do ROI: Reduces labor requirements for operation and minimizes risk of catastrophic failure through proactive monitoring.

Modular Base Frame & Passarelas | Base Técnica: Pré-montado, módulos estruturais aparafusados | Benefício Operacional: Simplifies site installation and foundation work, improves access for safe maintenance | Impacto do ROI: Reduz o tempo de instalação em até 35%, accelerating timetooperation and improving technician safety.

HeavyDuty Discharge Conveyor | Base Técnica: Impactresistant idlers at loading point and chevron belting | Benefício Operacional: Alças afiadas, heavy crushed slag without belt damage or spillage at transfer points | Impacto do ROI: Eliminates chronic conveyor maintenance issues, ensuring consistent product flow to stockpile.

Dust Suppression Ready Design| Base Técnica: Preplumbed nozzle mounting points at key dust generation zones | Benefício Operacional: Allows easy integration of water spray systems to control particulate emissions during crushing| Impacto do ROI: Facilitates compliance with environmental standards without costly postinstallation modifications.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Average Jaw Plant) | Nossa solução para planta de britagem de escória | Vantagem (% Melhoria) |
| : | : | : | : |
| Vida útil do forro (Escória Abrasiva)| 60,000 80,000 toneladas| 100,000 110,000 toneladas| +40% |
| Disponibilidade (Tempo de atividade)| ~85% (incluindo. mudanças de revestimento)| ~92% (incluindo. manutenção programada)| +7 pontos percentuais |
| Toneladas por hora (Effective)| Subject to fines packing| Consistent via prescreening grizzly| +25% (context dependent) |
| Instalação & Comissionamento| 45 semanas no local| 23 semanas com design modular| 35% redução de tempo |
| Consumo específico de energia| Baseline reference kWh/tonne| Field data shows reduction via optimized load control| 8% para 12% |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 150 para 600 toneladas por hora (TPH), depending on feed size and required product gradation.
Triturador Primário: Heavyduty jaw crusher model options from 42”x30” up to 60”x48” feed opening.
Requisitos de energia: Potência total instalada normalmente entre 200 quilowatts – 450 kW; configured for 400V/50Hz or other industrial standards.
Principais especificações de materiais: Crusher jaws manufactured from Mn18Cr2 or Mn22Cr2 alloy steel; main frame constructed from ST523 grade steel plate; abrasionresistant liners at all wear points.
Dimensões Físicas (Configuração típica): Pegada aproximada de 25m (eu) x 8m (C) x 7m (H). Semimobile skid versions available.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; componentes elétricos protegidos contra poeira; pacotes opcionais de aquecimento/resfriamento disponíveis.

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Complex – Blast Furnace Slag

Challenge A major steel producer faced daily bottlenecks at its aging slag dump. The existing crusher required biweekly liner checks and produced inconsistent aggregate size, limiting sales of the processed BFS aggregate.
Solution Implementation of a turnkey HighQuality Slag Crusher Plant with integrated grizzly feeder replaced the old system. The PLC automation allowed integration with their central control room.
Results Liner inspection intervals extended to six weeks. A disponibilidade da planta aumentou de ~78% para mais 90%. The consistent product quality enabled a new contract for railway ballast supply.

Copper Smelter – Slag Processing Yard

Challenge A smelter’s expansion project required onsite processing of granulated copper slag into construction sand. Space was limited,and rapid deployment was critical.
Solution A semimobile configuration of the Slag Crusher Plant was selected,fitted with specific jaw plates for granulated slag.The modular design allowed erection on a prepared pad within two weeks.
Results The plant achieved full design capacity of 250 TPH within three days of commissioning.The compact layout met site constraints,and the produced sand met ASTM C33 specifications for concrete work.

7. CONSIDERAÇÕES COMERCIAIS

Our HighQuality Slag Crusher Plants are offered in three primary tiers:
1. Configuração padrão: Inclui britador de mandíbula central,alimentador vibratório para ursos pardos,basic discharge conveyor,and motor starters.Priced as a capital equipment investment.
2. Configuração otimizada: Adds PLC automation,dust suppression ring main,escada & walkway packages,and upgraded wear liners.Includes an extended warranty package.Available via capital purchase or leasetoown financing plans.
3. Solução chave na mão: Full engineering,fornecer,testes de fábrica,civil works guidance,and commissioning supervision.Includes multiyear service agreements covering planned maintenance,inspeções,and preferential spare parts supply.Financing options including equipment rental are available.

Optional features include metal detection systems,magnet separators for tramp iron removal,custom conveyor lengths,and sound attenuation enclosures.Service packages range from basic technical support to fullservice maintenance contracts managed by our field engineers.

8.Perguntas frequentes

Q1 Is this plant compatible with our existing downstream screening and conveying equipment?
A1 Yes.The discharge height,largura do cinto,and speed of the main outfeed conveyor are engineered during quotation phase to match your existing layout.Product sizing can be adjusted through crusher setting changes within its designed range.

Q2 Qual é o impacto operacional esperado durante a instalação?
A2 For replacement projects,the modular design minimizes disruption.We provide detailed phasing plans.Often,the new plant can be assembled adjacent to the old one,followed by a scheduled tiein outage typically under one week.For greenfield sites,the reduced installation time accelerates project completion.

Q3 How does this solution address abrasive wear compared to standard manganese steel?
A3 We utilize premiumgrade alloyed manganese steels(Mn18Cr2/Mn22Cr2).Industry testing demonstrates these alloys develop a harder workhardened surface under impact,increasing service life in highabrasion applications like slag crushing by approximately 40%.

Q4 What are typical payment terms?
A4 For standard configurations,a deposit upon order confirmation followed by progress payments tied to major manufacturing milestones.Turnkey projects follow an agreed payment schedule based on equipment delivery,system erection,and successful performance testing.Commercial leasing structures are also available upon credit approval.

Q5 Can it handle wet or sticky slag?
A5 The integrated grizzly feeder provides significant benefit here,but extremely wet material can reduce screening efficiency.We recommend evaluating feed moisture content.Crusher design allows handling some moisture,but dedicated predrying may be needed if material adheres consistently.We can advise based on your specific sample analysis

Q6 What training is provided for our operators?
A6 Comprehensive training is included with Optimizedand Turnkey packages.It covers normal operation,troubleshooting via the PLC interface,procedimentos de segurança,and basic daily maintenance checks.Documentation includes detailed operationand maintenance manuals in English

Q7 What defines 'highquality' in this context beyond durability?
A7 It encompasses three pillars engineered reliability ensuring predictable uptime intelligent design features like prescreening that optimize total process flow not just machine outputand build quality using traceable materials that meet stated specifications providing longterm structural integrity