1. ABERTURA ACIONADA POR PAINPOINT

A gestão da escória é um gargalo persistente com custos tangíveis. Você está enfrentando esses desafios operacionais?
Taxa de transferência não confiável: Inconsistent crusher performance creates pileup at the furnace or converter, delaying tapping schedules and disrupting upstream production.
Tempo de inatividade excessivo: Falhas mecânicas frequentes, particularly from uncrushable tramp metal or abrasive materials, lead to unscheduled maintenance, altos custos de substituição de peças, and lost processing hours.
Altos custos operacionais: Desgaste prematuro dos martelos, forros, and rotors from highimpact crushing drives a continuous cycle of consumable expenditure and labor for changes.
Segurança & Riscos de limpeza: Dust generation during crushing and the handling of jagged, oversized slag fragments pose risks to personnel and create a problematic worksite environment.
Inflexible Output: Inability to adjust final product size efficiently limits your ability to meet specific grading requirements for different recycling or aggregate applications.

A questão central para os gerentes de fábrica é: how can you transform slag from a costly byproduct into a reliable, revenuegenerating stream without compromising primary production?

2. VISÃO GERAL DO PRODUTO: ODM SLAG CRUSHER PLANT

An ODM (Fabricante de design original) Slag Crusher Plant is a customengineered, stationary or semimobile processing system designed specifically for the reduction of metallurgical slag. Unlike standard offtheshelf crushers, an ODM plant is fabricated based on your specific slag analysis, capacidade necessária, e restrições do local.

Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: Slag from the ladle or stockpile is fed via apron feeder or conveyor. An initial grizzly section removes fine material bypassing the crusher.
2. Redução de tamanho primário: O triturador de núcleo (typically a robust impactor or jaw crusher) accepts large chunks (até 1m+) and reduces them to a manageable size (por exemplo, <200milímetros).
3. Tramp Metal Separation: A critical stage where an overhead magnetic separator removes ferrous tramp metal after primary crushing but before britagem secundária, protegendo equipamentos a jusante.
4. Britagem Secundária & Triagem: A secondary crusher (often a cone or impactor) further reduces material, which is then screened into specified product fractions (por exemplo, 010milímetros, 1040milímetros).
5. Estoque & Expedição: Sized products are conveyed to designated stockpiles for loading out.

Escopo de aplicação & Limitações:
Escopo: Ideal para usinas siderúrgicas integradas, fundições de cobre/níquel, and ferrous alloy producers processing aircooled blast furnace (namorado) escória, escória de forno de aço (BOF/EAF), and nonferrous slags with manageable metal content.
Limitações: Not designed for molten slag handling. Performance is contingent on accurate feed material analysis; slags with extremely high metallic yield or tenacious composite materials may require pretreatment or specific crusher configurations.

3. RECURSOS PRINCIPAIS

Conjunto de rotor para serviço pesado | Base Técnica: Forged steel rotor discs with highinertia design | Benefício Operacional: Sustains higher kinetic energy for effective breakage of dense slag lumps with less wear per ton processed | Impacto do ROI: Reduced specific power consumption (kWh/tonelada) and longer intervals between rotor service.

Ajuste Hidráulico & Proteção contra sobrecarga | Base Técnica: Integrated hydraulic cylinders for setting adjustment and automatic release upon uncrushable object entry | Benefício Operacional: Operators can adjust product size settings quickly under load; system protects itself from severe damage by tramp metal | Impacto do ROI: Minimizes risk of catastrophic failure events that cause days of downtime.

Sistema de revestimento resistente à abrasão | Base Técnica: Bolton liner plates manufactured from proprietary AR steel alloys (400500+ Brinell) in optimized wear zones | Benefício Operacional: Liners withstand extreme abrasion from crystalline slag structure, extending service life in highwear areas like impact aprons and breaker plates | Impacto do ROI: Lowers total cost of ownership through fewer liner changeouts and associated labor.

Enclosed Housing with Dust Extraction Ports | Base Técnica: Sealed crusher housing engineered with strategically placed flanges for connection to plant dust suppression or collection systems | Benefício Operacional: Significantly contains dust generated at primary impact points, melhorando a visibilidade do local e a qualidade do ar | Impacto do ROI: Reduces housekeeping costs and supports compliance with workplace environmental standards.

Passarela Modular & Acesso de manutenção | Base Técnica: Integrated platforms, escadas, and pullout sections designed around major service points (rotor, forros) per maintenance procedure study | Benefício Operacional: Technicians perform routine inspections, mudanças de revestimento, and major overhauls safely and efficiently with correct tool access | Impacto do ROI: Reduz o tempo de inatividade planejado para manutenção em até 30% based on field data comparisons.

Lubrificação Centralizada & Pontos de monitoramento de condição | Base Técnica: Manifolded lubrication lines routing from central stations to all key bearings; provision for sensor (vibração,temperatura) instalação | Operational Benefit Ensures consistent bearing lubrication critical in highshock environments; enables predictive maintenance protocols| ROI Impact Prevents bearing seizure failures extends component life reduces unplanned stoppages

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Solução padrão da indústria | ODM Slag Crusher Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (%)| 8085% (downtime for wear changes/breakdowns)| 9295% (designformaintenance access + sistemas de proteção)| +10% tempo de atividade operacional |
| Liner Life Primary Stage (Horas)| ~500600 hrs on abrasive BF slag| ~750900 hrs via optimized alloy/design| +40% usar vida |
| Eventos de dano de metal vagabundo| 23 significant incidents/year average| 80% reduction in related repairs |
| Consumo Específico de Energia| Benchmark varies; typically higher due to inefficient reduction| Lower kWh/ton via highinertia rotor & optimal chamber geometry| Os dados de campo mostram 812% melhoria |
| Consistência de rendimento (±%)| +/ 15% variance due to bridging/wear performance decay|< +/ 5% variance via controlled feed & adaptive crushing action| More predictable downstream process flow |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 150 TPH acima 600 TPH, based on feed characteristics and required product sizing.
Requisitos de energia: O acionamento primário do britador normalmente varia de 250 kW para 500 kW, dependent on model capacity; total plant connected load includes conveyors, telas,and auxiliaries.
Especificações de materiais:
Crusher housing/frame: Heavyduty structural steel plate (>25mm in stress areas).
Wear components: Manganese steel or chromium carbide overlays for hammers/impactor bars; AR plate liners (>400 BNH).
Rotor shaft material: Forjamento de liga de aço (por exemplo, 34CrNiMo6), testado ultrassonicamente.
Dimensões Físicas: Footprint is projectspecific; a typical primary/secondary skidmounted module may measure approximately (eu)20m x (C)8m x (H)7eu.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C, with optional features for dust sealing (IP65 on bearings)and highhumidity environments common in mill settings.

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Plant Blast Furnace Slag Processing

Desafio: A major steel producer faced frequent plugging and accelerated wear in their existing hammer mill circuit when processing coarse blast furnace slag containing occasional skulls.The resulting downtime was delaying hot slag pit clearing.
Solução: Implementation of an ODM Slag Crusher Plant featuring a deepchamber primary jaw crusher followed by an overhead magnetic separatorand secondary horizontal shaft impactor.The jaw's linear compression action effectively broke the tough skulls without stalling
Resultados: Throughput stabilized at 400 TPH.Plant availability increased from ~78%to93%.Wear costs on primary stage reduced by60%due to the jaw's more abrasionresistant plate design

Copper Smelter Recycling Converter Slag

Desafio: The client neededto liberateand recover entrained copper mattefrom lump converter slag while producinga consistentminus50mm aggregatefor construction sales Existing equipment struggledwith varying feed hardnessand caused excessive fines generation
Solução: A twostage ODM plant was configuredwitha primary impactcrusheroperatingin closed circuitwitha screen This allowedfor controlledimpactbreakingfor bettermetalliberationand recirculationof oversize
Resultados: Matte liberation efficiency improved allowingfor highermetal recovery ratesin downstreamprocessing Aggregateproduct cubicity met premiumspecifications enablinga20%increasein salesprice Fines generationwas reducedby15%

7.CONSIDERAÇÕES COMERCIAIS

ODM Slag Crusher Plants are capital investments priced accordingto capacity complexityand material specifications

Níveis de preços
– Base Configuration Skidmountedprimarycrushingmodulewith basic discharge conveyor Starting point formajor projects
– StandardizedPlant Includesprimarycrusher magnetic separator secondarycrusherscreen moduleand controlpanel The most commonturnkeysolution
– Fully CustomizedSystem Engineeredfor complexlayouts multipleproductsizes automatedmaterialhandlingandsophisticatedcontrols

Optional Features include advanced condition monitoring systems automated grease systems speciallinermaterials forextreme abrasion dust suppression cannon integrationand sound attenuation enclosures

Service Packages typicallycompriseawarrantyperiod followedby annualmaintenancecontracts offering scheduledinspections priorityparts supplyand experttechnical support Financing options suchas equipment leasingor project financingare often availablethroughpartner institutions tomatchcapitalexpendituretothe asset'sproduction lifecycle

Perguntas frequentes

Q1 Is an ODM plant compatible with our existing material handling system?
A Yes A core principleofODM fabricationis interfaceengineering We designfeedand discharge points conveyor heightsand control integrationtomatchyour currentlayout minimizingcivilwork

Q2 What data do you needto providefor an accurate proposal?
A Criticaldata includeslag sampleanalysis(chemicalcomposition hardnessabrasiveness) requiredhourlyannual tonnage incomingfeed sizemaximum lump size desiredfinalproductsizesand any siterestrictions

Q3 How does this solutionimpact our ongoing operational manning?
A The plantsaredesignedfor semiautomaticoperationfromacontrolroom Typically oneoperatorcan manage thecrushing circuit reducing directlabor comparedto multiplemobileunits Howevermaintenanceplanningrequirements remain

Q4 Whatisthetypical deliveryandlead timefrom orderto commissioning?
A For standardizedplants lead timesrangebetween26and36weeks dependingon component sourcing Custom designsrequire additional engineeringtime Lead timeis definedafter finalprocess designcriteriaare approved

Q5 São oferecidas garantias de desempenho?
A Yes contractsinclude guaranteedcapacity basedon agreed feedmaterial specifications as wellas guaranteed maximum power consumption Product sizing guaranteescan alsobe providedforspecific configurations

Q6 How are spare parts managed longterm?
A We maintaindetailed billofmaterialsforall fabricatedplants Criticalspare partkits arerecommendedat purchase Comprehensive drawingsandsupplychain informationare providedtothe client ensuringpartstraceabilityfor decades

Q7 Can the plant handle variationsinslag composition between differentfurnacesor campaigns?
A The robustdesignaccommodatesnormalvariability Featureslike hydraulic adjustmentallowoperatorsto compensate For majorschangesin materialcharacteristics(eg switchingfromBFtoEAFslag)a processreviewis recommended