1. ABERTURA ACIONADA POR PAINPOINT

A sua operação de manuseio de escória é um gargalo persistente e uma fonte de custos ocultos?? Para gerentes de fábrica e empreiteiros de engenharia, os desafios do processamento de escória metalúrgica são multifacetados. Você está experimentando:
Tempo de inatividade excessivo: Entupimento frequente, ponte, and abrasive wear in primary crushing stages halting your entire material recovery line?
Taxa de transferência imprevisível: Inconsistent feed size and composition from ladles leading to capacity fluctuations and missed processing targets?
Altos custos operacionais: Premature failure of crusher components not designed for extreme abrasion, coupled with high energy consumption per ton processed?
Ineficiência de recuperação: Inadequate liberation of metallic fractions from the slag matrix, leaving valuable material in your waste stream and reducing overall plant revenue?
Segurança & Maintenance Burdens: Laborintensive clearing of jams and the risks associated with manual handling of large, irregular slag pieces?

Esses problemas impactam diretamente seus resultados financeiros por meio da perda de produção, increased maintenance labor, and suboptimal metal recovery. A questão central é: como você consegue confiabilidade, highvolume slag reduction with predictable operating costs?

2. VISÃO GERAL DO PRODUTO: PLANTA DE TRITURADOR DE ESCÓRIA

A Slag Crusher Plant is a purposebuilt, sistema de processamento estacionário ou semimóvel projetado para o processamento primário, secundário, and sometimes tertiary reduction of aircooled or granulated metallurgical slag. Its function is to liberate entrapped metal (ferrous and nonferrous) from the slag matrix and produce a consistently sized aggregate for sale or further processing.

Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: Runoffurnace slag is fed via loader or conveyor into a robust grizzly or scalping screen to remove fine material (30milímetros) ignorando o britador primário.
2. Britagem Primária: Material de tamanho grande (+30mm to +500mm) enters a heavyduty jaw crusher or impact breaker designed to handle extreme shock loads and abrasion.
3. Separação de Metais & Britagem Secundária: The crushed product is conveyed past an overhead magnetic separator to extract liberated ferrous metal. Remaining material may pass through a secondary cone or impact crusher for final sizing.
4. Dimensionamento Final & Estoque: Material is screened into specified aggregate fractions (por exemplo, 05milímetros, 510milímetros, 1020milímetros) através de peneiras vibratórias e transportados para estoques.

Escopo de aplicação & Limitações:
Escopo: Ideal para usinas siderúrgicas integradas, fundições de cobre, produtores de ferroligas, e pátios autônomos de processamento de escória que lidam com altos-fornos (namorado), forno de oxigênio básico (BOF), forno elétrico de arco (EAF), ladle, e escórias não ferrosas.
Limitações: Not designed for primary rock mining applications. Performance on extremely sticky or highmoisture slags may require predrying or specialized feed systems.

3. RECURSOS PRINCIPAIS

Triturador Primário Pesado | Base Técnica: High Manganese Steel Jaws & Estrutura Reforçada | Benefício Operacional: Sustained performance under extreme shock loads from large, irregular slag pieces with minimal deformation | Impacto do ROI: Reduces unplanned crusher downtime by up to 40% and extends jaw life by over 60% em comparação com designs padrão.

Circuito Integrado de Separação Magnética | Base Técnica: Overband SelfCleaning Electromagnets positioned at optimal discharge points | Benefício Operacional: Contínuo, automated recovery of liberated ferrous metal directly from the crushed stream without manual intervention | Impacto do ROI: Aumenta as taxas de recuperação de metal em 1525%, creating a direct revenue stream from what was previously waste.

AbrasionResistant Material Flow System | Base Técnica: Revestimentos de aço AR400/500 em tremonhas, cai, and skirts; impact beds on conveyor load zones | Benefício Operacional: Dramatically reduces wearrelated failures in highimpact areas, maintaining consistent flow geometry | Impacto do ROI: Lowers annual liner replacement costs by an average of 35% and reduces conveyor belt damage.

Automação PLC Centralizada & Monitoramento | Base Técnica: Programmable Logic Controller with HMI touchscreen for system control; motor current sensors and bearing temperature monitors | Benefício Operacional: Enables oneoperator control of the entire plant with realtime alerts for abnormal conditions like overloads or blockages | Impacto do ROI: Optimizes power consumption per ton by up to 20% through controlled sequencing; reduces required operational manpower.

Design modular montado em skid (Opcional) | Base Técnica: Preassembled crusher modules on heavyduty structural skids with integrated walkways | Benefício Operacional: Significantly reduces civil works requirements and onsite installation time by up to 70% | Impacto do ROI: Comissionamento mais rápido acelera o tempo de receita; facilitates future relocation if site requirements change.

Dedicated Slag Crusher Plant Dust Suppression System | Base Técnica: Nozzle arrays at transfer points connected to a highpressure pump unit with moisture sensors | Benefício Operacional: Effectively controls fugitive dust at source without overwetting material which can cause downstream handling issues | Impacto do ROI: Ensures compliance with site environmental standards; protects other machinery from abrasive dust ingress.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Solução padrão da indústria | This Slag Crusher Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade / Tempo de atividade| ~7580%, frequent jamming/clogging incidents| >92%, engineered feed system & projeto da câmara de britagem| +15% disponibilidade operacional|
| Custo de desgaste por tonelada processada| Alta variabilidade; frequent liner/impeller changes| Predictable cost; extendedlife components documented| 35% redução média|
| Eficiência de recuperação de metal (%)| Manual picking postcrushing or singlestage magnetic separation| Multistage liberation with optimized magnetic separation points| +20% ferrous recovery yield|
| Consumo de energia (kWh/tonelada)| Often overlooked; oversized motors running constantly| PLCcontrolled optimized start/stop sequences & VFDs em alimentadores| 18% redução média|
| Instalação / Tempo de comissionamento| Extensive field fabrication & alinhamento (1216 semanas)| Pretested modular skids requiring connection only (68 semanas)| 50% site construction time|

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 50 TPH acima 300 TPH de escória processada.
Opções do britador primário: Maldito Mandíbula (900 x 600mm to 1500 x 1200mm) or Primary Impact Crusher with hydraulic adjustment.
Requisitos de energia: Carga total conectada normalmente entre 250 quilowatts – 800 kW dependendo da configuração; supplied for 415V/3Phase/50Hz or as specified.
Principais especificações de materiais:
Crusher Jaws/Hammers/Blow Bars: Aço Manganês Premium (1822% Mn).
Liners/Chutes/Wear Plates: Minimum AR400 Steel.
Structural Frames & Patins: HeavyDuty Pentaplate / IS2062 E350 Grade Steel.
Correia transportadora: Minimum EP630/4 rated for abrasion resistance.
Dimensões Físicas (Typical Modular Plant): Length ~40m x Width ~12m x Height ~9m (excluindo funil de alimentação).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 10°C a +45°C; dust suppression system maintains operation within PM10 emission standards.

6. CENÁRIOS DE APLICAÇÃO

Usina Siderúrgica Integrada – Processamento de Escória BOF

Desafio: A major steel producer faced severe bridging in their existing crusher feed hopper when processing large BOF slag lumps (>800milímetros), causando tempo de inatividade diário. Metal recovery was inefficient using a single magnet after crushing.
Solução: Implementation of a custom Slag Crusher Plant featuring a vibrating grizzly feeder with stepped grizzly bars to break bridges ahead of a deepchambered jaw crusher. Two overband magnets were installed—one precrusher for loose metallics and one postprimarycrusher.
Resultados: Bridging incidents eliminated entirely. A disponibilidade da planta aumentou de 78% para >94%. Ferrous metal recovery improved by 22%, paying back the system’s capital cost in under two years through recovered metal value alone.

Contratante independente de processamento de escória

Desafio: A contractor servicing multiple smalltomedium EAF mills needed a portable solution that could be relocated between sites every 1824 months but required consistent high throughput without lengthy setup times.
Solução: A fully skidmounted Slag Crusher Plant was supplied on four modular sections (feed module with scalper, primary crusher module, screening/magnet module). All modules featured quickdisconnect electrical/pneumatic connections.
Resultados: Relocation time between sites reduced from three months to four weeks due to minimal civil work required at new locations. Consistent throughput of ~120 TPH maintained across different site configurations.

7. CONSIDERAÇÕES COMERCIAIS

Our Slag Crusher Plants are offered in three primary tiers based on capacity and automation level:

1. Planta de serviço padrão (<100 TPH): Focuses on core reliability with essential features like primary crushing and magnetic separation—ideal for smaller operations prioritizing capital efficiency.
2. Planta para serviços pesados (100 – .200 TPH):) Our most common configuration includes full abrasion protection package advanced PLC automation multistage sizing/screening—designed for maximum total costofownership savings in continuous operation
3.
4.HighCapacity/Turnkey System (>200 TPH):) Includes all heavyduty features plus optional secondary crushing stage automated sampler complete dust collection baghouse system project management services

Recursos opcionais incluem:
Sistemas automatizados de lubrificação com graxa
Thermal camera monitoring for bearings
Advanced aggregate cubicity shaping kit
Onboard diesel generator power pack

Service Packages range from basic commissioning/spare parts supply upto comprehensive annual maintenance contracts including scheduled wear part replacement

Financing options including equipment leasing rentalpurchase agreements are available subjecttoqualification providing flexibilityincapitalexpenditureplanning

8.Perguntas frequentes:

Q1 How do I determine if my specific typeofslag requiresajawcrushersoranimpactcrushersastheprimaryunitintheslagcrushersplants?
A1 The choice dependsonslag characteristics Jaw crushers are generally preferredforhighlyabrasive dense slagswithcompressivestrengthlikeaircooledBFslag duetotheirdirectforceandslowerspeed minimizing wear Impactors can offer higher reduction ratiosandbetter particle shapeforlessabrasive slags like someEAFslag We analyze your samplematerialin our labtoprovideadatabacked recommendation

Q2 Whatisthetypicalinstallationfootprintandfoundationrequirementsforaskidmountedslagcrushersplants?
A2 While significantly reduced comparedtotraditional plants level compacted groundoraminimalconcretethicknesspadissufficientforskid placement Major civil workislimitedtofeedhopperpitsandfinalproducttunnelconveyors if applicable Detailed foundation drawings are providedforsitepreparation

Q3 CananexistingslagcrushersplantsbeupgradedwithyourkeyfeaturesliketheenhancedmagneticcircuitorPLCautomations?
A3 Yes many components suchasoverbandmagnets advancedlinersandcontrol systems can be retrofitted ontoexistinginfrastructure Our engineers can conductanauditofyourcurrentsetupandproposephasedupgradestoimproveperformanceandROI

Q4 Howdoyouquantifythepotentialmetalrecoveryimprovementbeforepurchases?
A5 We conductarepresentativesampletestingprograminvolvinglaboratoryscalecrushingandmagneticseparationonyoursuppliedslag This generatesametallurgicalbalancereportprojectingliberationratesandrecoverypotentialwithdifferentmachineconfigurations providinganevidencebased forecast

Q5 Whatistheleadtimefromordertocommissioningforastandardheavydutyslagcrushersplants?
A6 Forstandarddesignsintheheavydutyrange leadtimesaveragebetweenfivesevenmonths This includesmanufacturing factorytesting disassemblyforshipmentandreassemblyonyoursite Modularskiddedunits reduceonsiteassemblytimebyoverhalfcomparedtopiecebuilt plants