1. ABERTURA ACIONADA POR PAINPOINT

O gerenciamento de escória é um gargalo crítico, mas caro. Material de alimentação inconsistente, abrasive wear, and regulatory compliance create persistent operational headaches that directly impact your bottom line. Você está enfrentando esses desafios?

Tempo de inatividade não planejado & Alta manutenção: The highly abrasive nature of slag rapidly degrades standard crusher components, leading to frequent breakdowns. Each hour of unscheduled downtime for liner replacement or repairs can cost thousands in lost processing capacity and labor.
Taxa de transferência inconsistente & Qualidade do Produto: Variable slag composition—from lump size to hardness—causes feed surges and chokeups in conventional crushers. This results in unpredictable output gradation, affecting downstream material handling and sales specifications.
Riscos de conformidade regulatória: Noncompliant equipment can introduce restricted substances into your processed material or fail environmental site audits. The financial and reputational risk of violating RoHS, WEEE, or similar directives is significant.
Custos operacionais ocultos: Excessive energy consumption from inefficient crushing, combined with the constant cost of nonspecialized wear parts, silently erodes profit margins on what should be a valuable recycled product.

A questão central para os gerentes de fábrica é esta: como você pode alcançar confiabilidade, compliant slag reduction without sacrificing operational efficiency or facing constant maintenance cycles?

2. VISÃO GERAL DO PRODUTO

UM RoHS Compliant Slag Crusher Plant is a purposeengineered stationary or semimobile crushing system designed specifically for the rigorous reduction of metallurgical slag (alto-forno, forno de aço, etc.) while guaranteeing that all materials in contact with the feedstock comply with the Restriction of Hazardous Substances (RoHS) directive.

Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: Slag is fed via loader or conveyor into a hopper, often passing through a grizzly to bypass fines and direct only oversize material to the crusher.
2. Britagem Primária: O triturador de núcleo (typically a robust jaw or impact crusher) reduces large slag lumps to a manageable size using highinertia forces.
3. Descarga & Transporte: Crushed material is discharged onto a closedloop conveyor system, built with RoHScompliant components, para transporte para a próxima etapa (secondary crushing or stockpiling).
4. Supressão de poeira: Sistemas de pulverização integrados controlam as emissões de partículas nos pontos de transferência, maintaining site environmental standards.

Escopo de aplicação: Ideal for steel plants, fundições, metal recycling yards, and aggregate producers processing slag into valuable construction aggregates or feedstock.
Limitações: Not designed for primary ore reduction or extremely highmoisture materials without preprocessing. Maximum input lump size is defined by specific plant configuration.

3. RECURSOS PRINCIPAIS

RoHSCompliant Material Construction | Base Técnica: Specification of all wear parts, forros, selos, and paints to exclude lead, cádmio, mercúrio, hexavalent chromium, PBBs, and PBDEs | Benefício Operacional: Eliminates risk of contaminating processed slag aggregate with restricted substances, ensuring product meets global market compliance standards | Impacto do ROI: Protects against costly product rejection, legal penalties, and preserves access to regulated markets.

AbrasionOptimized Crushing Chamber | Base Técnica: CADoptimized geometry and kinematics to ensure optimal impact angles and reduced sliding friction against wear surfaces | Benefício Operacional: Directs energy into breaking slag rather than grinding components; extends wear part life by up to 40% em comparação com câmaras padrão | Impacto do ROI: Reduces consumables cost per ton and increases mean time between maintenance intervals.

Rotor para serviço pesado & Conjunto de rolamento | Base Técnica: Highmass rotor design for superior inertia coupled with oversized spherical roller bearings rated for extreme shock loads | Benefício Operacional: Maintains consistent crushing force through variable feed conditions; prevents stalling and ensures stable power draw | Impacto do ROI: Delivers higher throughput with fewer fluctuations, maximizing plant capacity utilization.

Ajuste Hidráulico Inteligente & Limpeza | Base Técnica: PLCcontrolled hydraulic system for setting adjustment and automatic uncrushable material release (quando aplicável) | Benefício Operacional: Allows operators to adjust product size quickly; minimizes downtime from tramp metal or uncrushables by reversing the action in seconds | Impacto do ROI: Enhances operational flexibility and protects the crusher from catastrophic damage events.

Integrated MultiStage Dust Management | Base Técnica: Enclosed conveying with strategically placed spray nozzles and optional baghouse connection points | Benefício Operacional: Actively suppresses dust at source points like feed inlet and discharge chutes; maintains visible emissions within permit limits | Impacto do ROI: Reduces housekeeping labor costs and avoids potential regulatory fines for airborne particulate.

Lubrificação Centralizada & Monitoramento de condição | Base Técnica: Automated lubrication system for key bearing points with feedback sensors for flow verification | Benefício Operacional: Garante que componentes críticos recebam lubrificação correta sem intervenção manual; provides early warning of potential faults | Impacto do ROI: Prevents bearing failures—a leading cause of major downtime—and reduces routine maintenance manhours.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (NonSpecialized Crusher) | RoHS Compliant Slag Crusher Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Vida útil da peça (Forros de manganês) | 3045 days in severe slag duty | 6075 days under same conditions| +60% para +100% |
| Consumo específico de energia (kWh/tonelada)| Altamente variável; spikes with hard feed| Consistent draw within ±5% of target| Até 15% mais eficiente |
| Documentação de Conformidade| Generic MTRs; may contain noncompliant elements| Full Material Declaration file per EU 2015/863| 100% traceable compliance |
| Disponibilidade Média (%)| ~80%, affected by abrasive wear downtime| Consistentemente >92%, due to designed reliability features| +12 pontos percentuais |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 50 400+ toneladas por hora (TPH), depending on feed size and required product gradation.
Requisitos de energia: Motor do britador primário de 90 kW para 315 kW; total plant connected load includes conveyors (~1575 kW) and ancillary systems.
Especificações de materiais: All contact parts certified RoHS compliant via mill test reports (MTRs). Crusher housing constructed from hightensile steel plate (>350 Limite de escoamento em MPa).
Dimensões Físicas (Planta típica montada em skid): Length ~18m x Width ~5m x Height ~6m. Foundation requirements are minimized due to integrated support frame.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Electrical components rated IP65 for dust and water ingress protection.

6. CENÁRIOS DE APLICAÇÃO

Steel Mill Aggregate Production | Desafio: A European steel mill needed to process blast furnace slag into a saleable road base aggregate but faced export restrictions due to potential heavy metal leaching from standard crushing equipment. Unplanned liner changes were causing 1215 hours of monthly downtime.| Solução: Installation of a turnkey RoHS Compliant Slag Crusher Plant featuring an impact crusher with fully documented compliant wear parts.| Resultados: Achieved continuous certification for aggregate exports within the EU market. Wear part life increased from an average of 6 semanas para acabar 14 semanas. Annual maintenance downtime related to crushing was reduced by approximately 65%.

Metal Recycling Yard Expansion | Desafio: A recycler processing EAF (Electric Arc Furnace) slag experienced frequent jams in their existing jaw crusher from metallic inclusions ("ferro vagabundo"), leading to dangerous clearing procedures and inconsistent output sizes.| Solução: Implementation of a RoHS Compliant Slag Crusher Plant centered on a jaw crusher equipped with automatic hydraulic toggle release system.| Resultados: Tramp iron events are cleared in under two minutes remotely versus over an hour manually. Product consistency improved significantly (±10mm tolerance), increasing its market value as a controlled fill material.

7. CONSIDERAÇÕES COMERCIAIS

Our RoHS Compliant Slag Crusher Plants are offered in three primary tiers:

1. Camada de configuração básica: Includes core compliant crusher unit on skid frame plus primary discharge conveyor meeting essential specifications.
2. Nível de produção otimizado: Adds integrated prescreen grizzly section secondary conveyor loop dust suppression package basic PLC control panel
3. Turnkey Solution Tier Comprises full plant design installation commissioning services extended warranty package remote monitoring capability

Optional features include magnetic separation units sound attenuation enclosures custom discharge heights

Service packages range from annual inspection plans through comprehensive scheduled maintenance contracts including guaranteed wear part supply

Flexible financing options including equipment leasing rentaltoown agreements are available subject to credit approval

8.Perguntas frequentes

Q1 Are your plants compatible with existing conveyors feeders?
A1 Yes our plants are engineered as modular systems Standard discharge heights belt widths can be specified during design phase ensuring integration into current layouts

Q2 How does using compliant parts affect durability compared traditional manganese steel?
A2 Field data shows no compromise Modern compliant alloys are engineered specifically for abrasion resistance Their performance gain comes from optimized chamber design not just material hardness alone

Q3 What documentation do you provide prove compliance?
A3 We supply full Material Declaration forms technical files detailing each component along mill test reports MTRs certifying absence restricted substances per latest amendment directive

Q4 What typical implementation timeline look like?
A4 For standard skid mounted plant delivery typically takes weeks following order Factory acceptance testing available Installation commissioning requires additional weeks depending site readiness complexity

Q5 Can this plant handle other materials besides metallurgical slags?
A5 While optimized it effectively processes similar hard abrasive industrial byproducts such as ferroalloy silicon carbide However we recommend consultation application review ensure optimal configuration