1. ABERTURA ACIONADA POR PAINPOINT

Gerenciando escória, a challenging byproduct of metal production, directly impacts your plant’s bottom line and operational continuity. Você está enfrentando esses desafios persistentes?
Tempo de inatividade não planejado: Frequent breakdowns of underengineered crushers halt your entire material handling chain, costing thousands per hour in lost processing time and labor.
Desgaste Excessivo & Custos de manutenção: A natureza altamente abrasiva da escória degrada rapidamente os componentes de britagem padrão, levando a gastos insustentáveis ​​com peças de reposição e mão de obra de manutenção.
Saída inconsistente & Gargalos: An illmatched crusher produces uneven particle size distribution, causing downstream screening inefficiencies and storage issues, ultimately delaying shipment to your customers.
Altos custos operacionais: Inefficient power consumption and the need for secondary or even tertiary crushing stages erode profit margins on what should be a valuable recycled product.

A questão central para os gerentes de fábrica é: how do you transform this abrasive liability into a consistent, profitable stream without compromising reliability? A solução está em especificar um projeto específico planta de triturador de escória.

2. VISÃO GERAL DO PRODUTO

UM planta de triturador de escória is a stationary or semimobile system engineered specifically to reduce large chunks of aircooled or granulated metallurgical slag into precisely graded aggregates. Unlike generic rock crushers, it is designed from the ground up to withstand extreme abrasion and intermittent tramp metal.

Fluxo de Trabalho Operacional:
1. Recebimento Primário & Alimentação: Slag is delivered via dump truck or loader into a robust hopper, often equipped with a grizzly feeder to bypass subsize material and protect the primary crusher.
2. Redução de tamanho primário: Um britador de mandíbula resistente ou quebra-impacto realiza a britagem inicial, reducing large slabs to manageable diameters (tipicamente <200milímetros).
3. Britagem Secundária & Triagem: O material é transportado para um cone secundário ou britador de impacto para redução adicional. The crushed output is then screened via vibrating screens to separate product into specified size fractions (por exemplo, 05milímetros, 510milímetros, 1020milímetros).
4. Manuseio de Materiais & Estoque: Onspec aggregate is conveyed to designated stockpiles for loading and transport. Oversize material is recirculated back to the secondary crusher in a closedloop system.

Escopo de aplicação: Designed for ferrous (alto-forno, aço) and nonferrous (cobre, liderar) slags. Ideal for integrated metal plants and standalone slag processing yards.
Limitações: Not suitable for primary ore processing or extremely hard igneous rock. O tamanho da alimentação deve ser controlado de acordo com as especificações do projeto da planta.

3. RECURSOS PRINCIPAIS

Revestimentos Resistentes à Abrasão para Serviços Pesados | Base Técnica: Fundições de ferro branco com alto teor de cromo ou aço manganês | Benefício Operacional: Vida útil do revestimento aumentada em 60100% em comparação com materiais padrão, drastically reducing changeout frequency | Impacto do ROI: Lowers costperton for wear parts and reduces maintenance downtime by up to 30% anualmente.

Sistema de proteção de metal para vagabundos | Base Técnica: Hydraulic or pneumatic release mechanisms on crushers; metal detectors on feed conveyors | Benefício Operacional: Prevents catastrophic damage from uncrushable metals mixed within slag | Impacto do ROI: Eliminates risk of major rotor or shaft damage, protecting a capital asset worth hundreds of thousands.

PLCBased Automated Control Panel | Base Técnica: Centralized programmable logic controller with load management and fault diagnostics | Benefício Operacional: Permite controle de operador único, otimiza o consumo de energia, and provides clear alarm indicators for rapid troubleshooting | Impacto do ROI: Reduces labor requirements and minimizes unplanned stops through predictive alerts.

Design modular montado em skid | Base Técnica: Patins de aço estrutural pré-montados para componentes principais | Benefício Operacional: Significantly reduces civil works and onsite installation time by up to 40% | Impacto do ROI: Faster commissioning gets your revenuegenerating operation online sooner with lower initial construction costs.

Alimentador Grizzly Vibratório para Serviço Pesado | Base Técnica: Robust feeder with adjustable grizzly bars for prescreening | Benefício Operacional: Removes fines prior to primary crushing, increasing throughput efficiency and reducing unnecessary wear on the primary chamber | Impacto do ROI: Melhora a capacidade geral da planta ao 1525% while lowering energy consumption per ton.

Sistema fechado de supressão de poeira | Base Técnica: Strategically placed spray nozzles at transfer points coupled with dust extraction vents | Benefício Operacional: Maintains compliant airborne particulate levels, ensuring a safer working environment and meeting regulatory standards | Impacto do ROI: Evita possíveis multas e paralisações de trabalho por descumprimento ambiental.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Planta trituradora genérica) | Nossa solução para planta de britagem de escória | Vantagem (% melhoria) |
|||||
| Vida útil da peça (Primário) | 3045 Dias | 6090 Dias | +100% |
| Disponibilidade de tempo de atividade do sistema | 8085% | 9295% | +12% |
| Power Consumption/Ton | Linha de base | Optimized motor loads & efficient drive design |18% |
| Rendimento do produto acabado | Variable sizing requiring recrush Consistent grading within spec bands Recrush volume reduced by ~25% |
| Instalação & Comissionamento| 812 Semanas 57 Semanas 40% timetooperation |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade de processamento: Configurável de 50 TPH acima 300 TPH.
Tamanho máximo de alimentação: Up to 800mm slab size (dependente do modelo).
Requisitos de energia: A carga total conectada normalmente varia de 150 kW para 450 kW; projetado para alimentação de tensão industrial padrão (400V/50Hz ou personalizado).
Especificações do britador: Primary jaw crusher sizes from 750x500mm up to 1200x1500mm; Secondary cone crushers with heavyduty mantle/bowl liners.
Especificações de materiais: Crusher housings in fabricated steel plate; Liners in Mn18Cr2 / Liga de alto cromo; Conveyor belts with high abrasionresistant covers.
Dimensões Físicas (Configuração típica): Footprint approximately 40m (eu) x 20m (C). Skid designs minimize foundation needs.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; sistema de supressão de poeira classificado para operação eficaz até 80% umidade relativa.

6. CENÁRIOS DE APLICAÇÃO

Reciclagem integrada de pátio de escória de usina siderúrgica

Desafio: A major steel producer faced escalating landfill costs for blast furnace slag and needed an onsite solution creating saleable aggregate. Their existing equipment suffered weekly liner failures.
Solution Implementation of a turnkey planta de triturador de escória featuring primary jaw crushing followed by secondary cone crushing with automated screening.
Results Achieved consistent production of three aggregate grades within six weeks of commissioning. Wear part lifecycle extended from three weeks to seven weeks. The operation converted a cost center into a profit stream within one year.

Contratante independente de processamento de escória

Challenge A contractor processing slag from multiple sources required high mobility between sites without sacrificing durability or capacity.
Solution A semimobile skidmounted planta de triturador de escória, where primary and secondary modules could be relocated independently via lowloader trailers.
Results Reduced site setup time from three weeks to five days per location through prewired modules. Disponibilidade da planta excedida 93%, allowing the contractor to fulfill multiple longterm supply contracts reliably.

7. CONSIDERAÇÕES COMERCIAIS

Our solutions are offered in clear pricing tiers based on capacity:
Nível I (200 TPH): Fully customized highvolume systems with advanced automation options.

Optional features include magnetic separators for residual metal recovery automated greasing systems remote monitoring telemetry packages extended dust control enclosures

Service packages range from basic preventive maintenance plans comprehensive annual service contracts including wear part supply financing options are available including leaseto own structures equipment loans tailored support project cash flow

8.Perguntas frequentes

What types of slag are suitable?
Designed primarily aircooled blast furnace basic oxygen furnace steel slags copper smelter slags Granulated slags may require specific feed arrangements due density

How does handle tramp metal?
Systems incorporate multiple protection layers including hydraulic release mechanisms primary jaw optional metal detectors feed conveyor automatically stop belt uncrushable object detected

Qual é o prazo de entrega típico da instalação?
For standard configurations lead time manufacturing ranges months Complete delivery installation commissioning typically completed weeks following arrival site

Can integrate existing conveyors screens?
Yes plants engineered modular basis can interface existing downstream equipment provided specifications match Our engineering team will review layout compatibility

What ongoing maintenance requirements?
Daily visual checks lubrication Weekly bolt tightening inspections Scheduled liner replacements based monitored wear rates Predictive maintenance data provided via control system alerts