1. ABERTURA ACIONADA POR PAINPOINT

Are you managing a steel plant or slag processing yard and facing persistent bottlenecks in your material recovery chain? The challenges with traditional slag handling are quantifiable and costly. Inconsistent feed size jams crushers, causing unplanned downtime that costs thousands per hour in lost production and labor. Abrasive slag components rapidly wear out standard crushing chambers, levando a frequentes, expensive liner replacements and parts inventory burdens. Além disso, inefficient separation results in valuable metallic content being lost to waste stockpiles, directly impacting your revenue recovery. Dust generation creates environmental and health compliance issues, while inflexible equipment cannot adapt to varying slag types or production demands.

A questão central para os gerentes de fábrica é clara: como você pode alcançar confiabilidade, highvolume slag processing with lower operating costs and maximized metal yield? The answer requires a purposeengineered system, not just a standard crusher.

2. VISÃO GERAL DO PRODUTO

UM Planta de britagem de escória is a stationary or semimobile integrated processing system designed specifically for the size reduction and liberation of metallic content from steel slag, escória de alto forno, and similar industrial byproducts. Ele transforma cru, lump slag into a graded, marketable aggregate while recovering ferrous metal for recycling.

Fluxo de Trabalho Operacional:
1. Britagem Primária & Triagem: Grandes pedaços de escória (até 1000 mm) are reduced by a primary jaw crusher. A preliminary screen removes fine material.
2. Separação Magnética (Primário): A suspended magnet over the conveyor extracts the majority of liberated ferrous metal postprimary crushing.
3. Britagem Secundária: A cone crusher or impactor further reduces the material to achieve optimal liberation of embedded metal.
4. Triagem Final & Separação: Material is classified into precise aggregate sizes (por exemplo, 05milímetros, 510milímetros, 1020milímetros). A second drum magnet ensures final metal recovery.
5. Estoque: Clean aggregate is conveyed to stockpiles; recovered metal is collected for sale or reuse.

Escopo de aplicação: Usinas siderúrgicas integradas, pátios autônomos de processamento de escória, mining operations handling abrasive materials.
Limitações: Not designed for highly corrosive chemical slags or as a primary ore processing plant without significant configuration changes.

3. RECURSOS PRINCIPAIS

HeavyDuty Vibrating Feeder | Base Técnica: Grizzly section with adjustable spacing | Benefício Operacional: Removes subgrade fines and prevents primary crusher overload | Impacto do ROI: Reduz o desgaste do britador em até 15% and improves overall throughput stability.

Jaw Crusher with Manganese Steel Jaws | Base Técnica: High compression crushing with optimized nip angle | Benefício Operacional: Effectively processes large, irregular slag lumps with high compressive strength | Impacto do ROI: Os dados de campo mostram um 2030% longer service life compared to standard jaws in abrasive applications.

Electromagnetic Suspended Magnet | Base Técnica: Deep magnetic field penetration across full conveyor width | Benefício Operacional: Recovers large tramp metal antes secondary crushing stages | Impacto do ROI: Protects downstream equipment from damage and captures highvalue scrap early in the process.

Liner Protection System (Cone/Impactor) | Base Técnica: Hydraulic adjustment and overload relief cylinders | Benefício Operacional: Allows quick clearing of uncrushables and protects major components from catastrophic failure | Impacto do ROI: Minimizes risk of costly repairs and reduces mean time to repair (MTTR) by hours.

Transporte Fechado & Pontos de supressão de poeira | Base Técnica: Sealed transfer points with strategically placed spray nozzles | Benefício Operacional: Controls airborne particulate at critical generation points | Impacto do ROI: Mitigates environmental noncompliance risks and reduces site cleanup costs.

Sistema de controle PLC centralizado | Base Técnica: Automated sequencing with fault annunciation | Benefício Operacional: Enables smooth plant startup/shutdown and provides operators with clear diagnostic information | Impacto do ROI: Lowers operator error potential and simplifies troubleshooting.

Design modular de deslizamento (Opcional) | Base Técnica: Preassembled structural frames for key modules | Benefício Operacional: Reduces civil works cost and accelerates onsite installation time by an estimated 30% | Impacto do ROI: Faster commissioning leads to earlier production revenue.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Slag Crusher Plant Solution | Vantagem (% melhoria) |
|||||
| Taxa de recuperação de metal | ~9092% | Até 9698% | +68% Colheita |
| Vida útil do forro (Estágio Primário) | 80,000 100,000 MT processed | 120,000 150,000 MT processed | +4050% Durabilidade |
| Disponibilidade de tempo de atividade do sistema 95% 97%+ +2% Disponibilidade |
| Specific Power Consumption Baseline 1015% reduction through optimized drive systems 1015% Energy Savings |
| Dust Emission at Transfer Points Often requires addon bag filters Meets standards via integrated suppression Lower Capex on Dedicated Filtration |

Based on scheduled maintenance adherence.

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 50 TPH acima 300 TPH.
Tamanho da alimentação: Accepts lump slag up to 1000mm edge length.
Requisitos de energia: Total connected load typically between 250kW 800kW depending on configuration; supplied for 415V/3Phase/50Hz or as specified.
Especificações de materiais: Primary wear parts (forros, maxilas) manufactured from Grade III Manganese Steel or equivalent AR plate; structural frames from heavyduty ISMC/ISMB sections.
Dimensões Físicas: Varia de acordo com a capacidade; um padrão 150 TPH plant footprint is approximately 35m (eu) x 22m (C) x 15m (H).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 10°C a +45°C; dust and weather protection standard for outdoor installation.

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Plant Slag Yard Retrofit

Desafio:
A major steel producer faced frequent breakdowns in their aging twostage crushing setup. A recuperação de metal foi ineficiente (~88%), leading to significant value loss in aggregate stockpiles. Tempo de inatividade excedido 15 horas mensais.
Solução:
Implementation of a turnkey Slag Crusher Plant featuring a robust grizzly feeder, deepfield magnetic separators at two stages, and an automated cone crusher for secondary reduction.
Resultados:
A recuperação de metal aumentou para mais 96%. System availability reached >97%, reducing monthly downtime to under <5 horas. The recovered additional metal paid for the plant's operational costs within eight months.

Contratante independente de processamento de escória

Desafio:
A contractor needed mobile flexibility but required higher volume than portable crushers offered. Their challenge was inconsistent feed material from multiple small steel mills.
Solução:
A semimobile Slag Crusher Plant built on modular skids with quickdisconnect electrical/utility connections was deployed.
Resultados:
The plant could be relocated between sites within one week using conventional heavy transport. This flexibility allowed the contractor to service multiple clients without capital duplication while maintaining highvolume processing efficiency above >120 TPH consistently across varied feed materials.

7. CONSIDERAÇÕES COMERCIAIS

Níveis de preços: Capital cost varies significantly based on capacity and automation level.
Nível de entrada: Manual/semiautomated plants up to ~75 TPH focus on core functionality.
Padrão: Fully automated plants (~75200 TPH), including PLC control dust suppression represent the most common investment range
Alta capacidade: Customengineered systems (>200 TPH) often include advanced monitoring systems like liner wear sensors

Recursos opcionais & Atualizações: Vibrating screen decks for additional product fractions; metal baler/shear for scrap processing; sistemas de lubrificação automatizados; remote monitoring via SCADA

Pacotes de serviços: Annual Maintenance Contracts (AMC), guaranteed spare parts supply agreements are available

Opções de financiamento: Equipment leasing structures are commonly offered through partner financial institutions

8.Perguntas frequentes

1.P:What if our incoming slag composition varies significantly?
UM:The design incorporates adjustable crusher settings variable speed feeders allowing operators finetune throughput product size based realtime feed characteristics ensuring consistent output quality

2.P:What are typical installation requirements?
UM:A level prepared base adequate electrical supply water connection dust suppression essential Detailed foundation layout drawings comprehensive utility specifications provided prior delivery facilitate smooth site preparation

3.P:Que manutenção contínua devemos esperar?
A.Primary maintenance involves regular inspection replacement wear parts like crusher liners conveyor belts spray nozzles Scheduled lubrication critical bearings drives Welldesigned plant provides easy safe access all service points reduce labor time

4.Q.How does this integrate with our existing material handling equipment?
A.Plants are engineered accept feed from your current loaders conveyors Output conveyors can be positioned suit your existing stockpiling loading arrangements Control systems can often interface with broader site networks

5.Q.What warranty support do you provide?
A.A standard warranty covers manufacturing defects major components typically months extended warranties available purchase Comprehensive documentation includes operation manuals parts lists recommended maintenance schedules ensure your team fully supported