1. ABERTURA ACIONADA POR PAINPOINT

A gestão da escória é um gargalo persistente com custos tangíveis. Você está enfrentando esses desafios operacionais?
Alto tempo de inatividade & Custos de manutenção: Frequent clogging and abrasive wear in standard crushers lead to unscheduled stops, excessive part replacement, e horas de processamento perdidas.
Inefficient Material Liberation: Inconsistent crushing fails to fully separate metal from slag, resulting in valuable ferrous recovery left in the waste stream and lost revenue.
Limitações de rendimento: An undersized or improperly configured slag crusher plant creates a backlog, stalling upstream steelmaking operations and downstream material handling.
Altos custos operacionais: Excessive power consumption from inefficient crushing mechanisms and the laborintensive management of multiple, disparate units erode profit margins.
Pó & Conformidade com ruído: Uncontrolled particulate emissions and noise levels from crushing operations risk regulatory noncompliance and create unsafe workplace conditions.

A questão para os gerentes de fábrica é clara: how can you transform slag from a costly byproduct into a streamlined, profitable recovery operation while ensuring reliability and compliance?

2. VISÃO GERAL DO PRODUTO

A modern Slag Crusher Plant is a purposebuilt, integrated processing system designed for the efficient reduction and liberation of slag from steel mills, fundições, e fundições. Its core function is to crush large slag lumps into finely graded aggregate, maximizing the recovery of entrapped metallic content.

Fluxo de Trabalho Operacional:
1. Britagem Primária: Grande alimentação de escória (até 1000 mm) is reduced by a heavyduty jaw crusher or impactor capable of handling highabrasion material.
2. Separação Magnética: Initial recovery of liberated metallic pieces via suspended or drum magnets integrated into the conveyor system.
3. Secundário & Britagem Terciária: Further size reduction via cone crushers or impactors to ensure complete metalslag liberation.
4. Triagem & Final Separation: Material is classified by vibratory screens; tamanho grande é recirculado, while correctly sized aggregate passes under additional magnetic separators for final metal extraction.
5. Stockpiling/Transport: Cleaned slag aggregate is conveyed to stockpiles for sale or reuse; recovered metal is collected for recycling.

Escopo de aplicação: Ideal para usinas siderúrgicas integradas, minimills, fundições de cobre, and ferrous/nonferrous foundries. Projetado para alto-forno (namorado) escória, escória de forno de aço, and similar metallurgical byproducts.

Limitações: Not designed for primary ore processing or extremely hard, nonmetallic minerals. Feed size and composition must be evaluated against plant design specifications.

3. RECURSOS PRINCIPAIS

Triturador de mandíbula para serviço pesado | Base Técnica: Manganese steel jaws with optimized nip angle | Benefício Operacional: Alças grandes, irregular slag lumps without bridging; resiste à abrasão extrema | Impacto do ROI: Reduz o tempo de inatividade do estágio primário em até 40%, lowering maintenance labor and parts costs.

Sistema Integrado de Separação Magnética | Base Técnica: Multiple stages of electro/permanent magnets at critical transfer points | Benefício Operacional: Maximizes ferrous metal recovery directly during material flow | Impacto do ROI: Increases metal yield revenue by capturing an additional 515% of residual ferrous content often missed in singlestage systems.

Sistema de controle PLC centralizado | Base Técnica: Automated process control with load monitoring and fault diagnostics | Benefício Operacional: Enables singleoperator oversight of entire crushing circuit; prevents equipment damage due to overloads | Impacto do ROI: Lowers manpower requirements and eliminates costly motor/gear failures due to tramp metal or blockages.

Circuito de transporte resistente à abrasão | Base Técnica: Forros de aço AR400, camas de impacto, and sealedforlife bearings on conveyors | Benefício Operacional: Dramatically extends belt and component life in highwear transfer zones | Impacto do ROI: Cuts annual conveyor maintenance costs by an average of 30% compared to standard systems.

Supressão de poeira & Contenção | Base Técnica: Pressurized water spray nozzles at crusher inlets/vibrating screens with enclosure panels | Benefício Operacional: Effectively controls airborne particulate at source | Impacto do ROI: Ensures environmental compliance avoids fines reduces housekeeping labor protects worker health.

Design modular montado em skid (Opcional) | Base Técnica: Preassembled modules on structural skids| Benefício Operacional: Significantly reduces onsite civil work installation time commissioning period| ROI Impact Cuts total project installation costs by up to 25% gets your operation generating revenue weeks faster

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Solução padrão da indústria | Nossa solução para planta de britagem de escória | Vantagem (% Melhoria) |
| : | : | : | : |
| Taxa de recuperação metálica | Singlestage magnetic separation after primary crush. | Multistage magnetic separation before after each crushing stage.| +1218% mais metal recuperado |
| Vida útil do revestimento (Primário)| Standard manganese jaws replaced every 46 meses.| Proprietary alloy composition heat treatment.| +6080% vida útil prolongada |
| Disponibilidade de tempo de atividade do sistema| ~80%, factoring in unplanned stops for clearing cleaning.| >92%, achieved via robust design automated protection.| +15% aumento nas horas produtivas |
| Consumo de energia por tonelada| Fixedspeed drives across all motors.| Configured with variable frequency drives (Inversores de frequência) on feeders conveyors.| 1015% menor custo de energia |
| Instalação & Comissionamento| 812 weeks field assembly wiring.| 46 weeks for skidmounted modular plants.| Implantação cerca de 50% mais rápida |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 50 TPH acima 300 Taxa de transferência de TPH.
Tamanho da alimentação: Accepts lump slag up to 1000mm edge length.
Tamanho final do produto: Adjustable output from 20mm to 50mm based on screen configuration.
Requisitos de energia: Carga total conectada de 150 kW para 800 kW depending on plant size; supplied at 415V/50Hz or customized voltage/frequency.
Principais especificações de materiais:
Crusher Jaws/Liners: Aço Manganês Premium / HighChrome Iron Alloy
Chassis/Skids: Heavyduty structural steel (É 2062)
Correia transportadora: Minimum EP400/3 with abrasionresistant top cover
Dimensões Físicas (for typical 100 TPH skid plant): Aprox.. Length 25m x Width 8m x Height 6m (excluindo funil de alimentação).
Faixa operacional ambiental: Designed for ambient temperatures from 10°C to +45°C dustladen environments includes provisions for dust extraction system connection

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Plant Blast Furnace Slag Processing Challenge Significant downtime on aging primary crusher causing upstream BF granulation pit overflow inconsistent product size affecting sales Solution Replacement with a turnkey Slag Crusher Plant featuring heavyduty primary impactor multistage magnetic separation automated control Results Achieved consistent throughput of120 TPH product sizing within spec increased metal recovery by15 tons per month eliminated unplanned downtime events

MiniMill Electric Arc Furnace (EAF) Slag Challenge Need for compact footprint solution limited space high dust generation creating compliance issues manual handling was laborintensive Solution Installation of a modular skidmounted Slag Crusher Plant with integrated dust suppression enclosures Results Plant operational within5 weeks of delivery dust emissions reduced below permissible exposure limits(PELO) labor requirement cut from3 shifts to1 shift oversight

Copper Smelter Slag Recovery Challenge Processing complex slag containing residual copper matte requiring careful handling achieve specific granulometry for further mineral processing Solution Customdesigned Slag Crusher Plant with specialized liner alloys slower crushing speeds minimize fines generation enhanced ventilation at transfer points Results Optimized particle size distribution increased copper concentrate grade in downstream flotation circuit improved working environment through better dust control

7 CONSIDERAÇÕES COMERCIAIS

Our Slag Crusher Plants are offered in three primary tiers:

1. Standard Configuration A costeffective solution covering core crushing screening basic magnetic separation ideal for welldefined consistent feed materials
2 Advanced Configuration Includes multistage VFDs advanced PLC automation highergrade wear materials recommended for maximum uptime complex feed
3 Custom Engineered Solutions Tailored layouts special material handling requirements integration with existing granulation or sorting systems

Optional Features Upgrades include:
• Metal Detectors NonFerrous Recovery Systems(Eddy Current Separators)
• Advanced Baghouse Dust Collection Systems
• Remote Monitoring IoT Data Logging Packages
• Extended Warranty Coverage Critical Components

Service Support We offer comprehensive packages:
• Annual Maintenance Contracts(AMC)with scheduled inspections parts discounts
• OnDemand Field Service Technician Support
• Wear Parts Kits ensuring optimal inventory levels

Financing Options Available through partner institutions include:
• Equipment Leasing Structures
• Term Loans
• RenttoOwn Programs

Request a detailed quotation based on your specific annual tonnage feed characteristics site layout required final product specifications

FAQ – SLAG CRUSHER PLANT SOLUTIONS

Q1 What are the key factors determining the right capacity size?
The primary factors are your daily monthly slag generation volume required final product size needed metallic recovery rate A detailed analysis of your feedstock including lump size distribution hardness metallic content ensures correct sizing

Q2 How does this plant integrate with our existing material handling system?
Our engineering team will review your current conveyor layouts feed discharge points We design transition hoppers chutes interface conveyors ensure seamless integration minimal disruption during installation Electrical controls can be adapted match your existing PLC network protocols

Q3 What is the expected operational lifespan major components?
With proper maintenance industry data shows core structural components last15+ years Major crushers screens have10+ year design life Wear parts like jaw liners impact hammers screen meshes are consumables their lifespan depends directly on throughput material abrasiveness typically ranging from6 months24 months

Q4 Você pode fornecer garantias de desempenho?
Yes Our proposals include guaranteed minimum throughput capacity under defined conditions guaranteed final product gradation We stand behind our equipment performance these metrics are contractually stipulated based on preagreed feedstock samples analysis

Q5 What does typical installation commissioning involve?
For skidmounted plants it involves site preparation foundation bolting electrical power cable connection For stationary plants it includes more extensive civil work Our team provides supervision commissioning support operator training We manage the process until plant acceptance signoff