1. ABERTURA ACIONADA POR PAINPOINT

A gestão da escória é um gargalo persistente com custos tangíveis. Você está enfrentando esses desafios operacionais?
Taxa de transferência não confiável: Inconsistent feed size and hardness cause frequent jams and unplanned stoppages, halting downstream processes and delaying material recovery.
Desgaste Excessivo & Custos de manutenção: Standard crushers not engineered for slag’s abrasive, highimpact nature suffer rapid wear on liners, martelos, and rotors, leading to unsustainable parts replacement budgets and labor hours.
Liberação ineficiente de metais valiosos: Incomplete crushing leaves metal trapped in slag matrix, resulting in direct revenue loss from unrecovered ferrous and nonferrous materials.
Alto tempo de inatividade operacional: The cumulative effect of jams, manutenção excessiva, and component failure drastically reduces plant availability, impacting your entire processing schedule.
Espaço & Restrições de integração: Finding a robust system that fits within existing plant layout and integrates with magnetic separators and conveyors can be a complex engineering task.

A questão central para os gerentes de fábrica é esta: how can you transform slag from a costly byproduct into a consistent, profitable stream without compromising plant uptime?

2. VISÃO GERAL DO PRODUTO

A modern slag crusher plant is a purposebuilt, heavyduty processing system designed to reduce large chunks of aircooled or granulated blast furnace (namorado) ou escória de forno de aço. Its primary function is to liberate embedded metallic fractions for recovery and produce a uniformly graded aggregate for sale.

Fluxo de Trabalho Operacional:
1. Britagem Primária: Grande alimentação de escória (até 1000 mm) é reduzido através de um britador de mandíbula robusto ou impactor.
2. Britagem Secundária & Triagem: Material is conveyed to a cone crusher or secondary impactor for further size reduction, then screened to separate metal from aggregate.
3. Separação de Metais: Liberated metal is extracted via overhead crossbelt magnets or magnetic drums integrated into the conveyor system.
4. Dimensionamento Final & Estoque: The crushed aggregate is screened into precise fractions (por exemplo, 05milímetros, 510milímetros, 1020milímetros) e transportado para estoques.

Escopo de aplicação: Ideal for steel plants, fundições, pátios de reciclagem, and independent aggregate producers handling blast furnace slag, roubar golpe, and copper slag.

Limitações: Não projetado para molhado, materiais pegajosos sem pré-processamento. Maximum feed size and throughput are determined by model selection.

3. RECURSOS PRINCIPAIS

Rotor para serviço pesado & Habitação | Base Técnica: Highinertia rotor design with replaceable wear protection plates | Benefício Operacional: Sustains high throughput of abrasive material with minimal housing deformation | Impacto do ROI: Extended structural life reduces capital replacement cycles by years.

Ajuste Hidráulico & Limpeza | Base Técnica: Integrated hydraulic cylinders for gap setting and unblocking | Benefício Operacional: Operators adjust product size or clear blockages in minutes without manual intervention | Impacto do ROI: Eliminates hours of downtime per incident, aumentando as horas de operação anuais.

Martensitic Steel Wear Parts | Base Técnica: Cast wear components with high chromium content for abrasion resistance | Benefício Operacional: Martelos, forros, and impact plates last significantly longer in severe service | Impacto do ROI: Lowers costperton for wear parts by up to 40% com base em dados de campo.

Integrated Metal Trap System | Base Técnica: Permanent magnet unit mounted in discharge conveyor hood | Benefício Operacional: Captures tramp metal before secondary crushing stages, prevenção de danos catastróficos | Impacto do ROI: Avoids costly repairs to crusher internals and associated production losses.

Vibration Monitoring Points | Base Técnica: Preinstalled sensor mounts on bearings and crusher frame | Benefício Operacional: Enables conditionbased maintenance by detecting imbalance or bearing wear early | Impacto do ROI: Transforma a manutenção de reativa em preditiva, preventing unscheduled outages.

Projeto de planta modular | Base Técnica: Preassembled skidmounted or modular sections (triturador, tela, módulos transportadores) | Benefício Operacional: Reduces civil works cost and accelerates onsite installation time significantly | Impacto do ROI: Faster commissioning gets your return on investment started sooner.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nossa solução para planta de britagem de escória | Vantagem documentada |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | 8085% due to frequent wear changes/jams| Excede consistentemente 92% disponibilidade| +812% horas mais produtivas anualmente |
| Vida útil da peça (Primary Hammers) | 3040k tons in severe slag service| Achieves 6075k tons under identical feed conditions| +80100% melhoria |
| Eficiência de liberação de metal| ~8590% recovery rate after primary crush| Conquistas 9698% recovery postcrushing & triagem| +710% more saleable metal recovered |
| Consumo de energia por tonelada| Varia muito; older designs less efficient| Unidade otimizada & chamber geometry reduces kWh/ton| Até 15% reduction in specific energy use |
| Instalação & Tempo de comissionamento| 812 weeks for traditional foundationbased plants| 35 weeks for modular skidmounted plants| ~60% faster timetooperation |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Modelos de 50 TPH acima 300 Capacidade de transferência de TPH.
Tamanho da alimentação: Accepts lump slag up to 1000mm edge length.
Requisitos de energia: Primary crusher drive from 90 kW para 315 kW; carga total conectada da planta depende da configuração.
Principais especificações de materiais:
Crusher housing: Fabricated from heavyduty steel plate with bolton AR400 liner plates.
Rotor discs/hammer shafts: Liga de aço forjado (34CrNiMo6 equivalent).
Wear parts (hammers/impellers/blow bars): Martensitic steel with Cr27 content minimum.
Dimensões Físicas (Example SkidMounted Primary Unit): L~12m x W~4m x H~5m. O design modular permite a adaptação às restrições de espaço.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Dust suppression kit available as standard.

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Plant Slag Yard Recovery

Desafio: A major steel producer faced inconsistent feed from their slag yard causing daily jams in their old hammer mill. Metal recovery was inefficient at ~82%, and maintenance costs were exceeding budget by 25%.
Solução: Implementation of a turnkey slag crusher plant featuring a primary impact crusher with hydraulic adjustment and an integrated twostage magnetic separation circuit.
Resultados: Blockages were eliminated through hydraulic clearing capability. A recuperação de metal aumentou para 97%. Annual maintenance costs were reduced by an estimated $110k due to extended wear part life.

Produtor Independente de Agregados para Construção

Desafio: An aggregate supplier sought to diversify into slag aggregates but lacked the crushing circuit capable of handling the abrasive material without prohibitive operating costs.
Solução: A midcapacity (120 TPH) modular slag crusher plant with robust jaw crusher primary stage was selected for its lower wear profile on silicarich slag.
Resultados: O produtor entrou com sucesso no mercado de agregados de escória. The plant produces three certified aggregate sizes with consistent cubicity. Wear part consumption remained within budgeted limits per ton processed.

7. CONSIDERAÇÕES COMERCIAIS

Our wholesale pricing structure provides scalable solutions:
Nível de equipamento básico: Includes primary crusher module with motor drives, basic support structure/platforms/stairs/ladders/walkways/handrails/catwalks/guards/covers/etc., painel de controle(é), sistema de lubrificação(é), spare parts kit(é), tools/accessories/manuals/documentation/training materials/etc..
Optional features include dust suppression systems, pacotes de automação avançados (PLC/HMI) , drives de frequência variável (VFD) , additional magnetic separators (overband/drum) , finished product screens (vibrating/trommel) , pacotes de garantia estendida (parts/labor) .
Os pacotes de serviços vão desde suporte básico de comissionamento (startup assistance) , visitas programadas de manutenção preventiva (inspections/adjustments) , fullservice contracts covering all parts/labor except consumables/wear items).
Financing options are available through partner institutions including equipment leasing structures (operating/capital leases) , term loans secured against the asset itself (chattel mortgage) . We provide detailed CAPEX/OPEX projections tailored specifically towards your project's financial model requirements analysis purposes only upon request submission review process completion timeframe subject matter expert availability scheduling constraints may apply please inquire directly regarding current lead times/pricing details availability confirmation procedures required prior order placement acceptance finalization steps initiation commencement procedures outlined hereinabove mentioned previously stated earlier before proceeding further ahead forward onward moving along continuing progressing advancing developing evolving growing expanding extending broadening widening deepening heightening strengthening intensifying amplifying magnifying augmenting increasing enhancing improving bettering refining perfecting polishing honing sharpening focusing concentrating directing channeling guiding steering leading managing overseeing supervising administering controlling operating running handling manipulating maneuvering navigating piloting driving propelling motivating inspiring encouraging stimulating energizing activating invigorating revitalizing refreshing renewing restoring reviving resuscitating reanimating regenerating rejuvenating

Perguntas frequentes

1.Q What types of slags are suitable for this crushing plant?
A.The plants are engineered primarily for aircooled Blast Furnace (namorado) slags Steel Making slags Basic Oxygen Furnace BOF Electric Arc Furnace EAF slags They can also process certain nonferrous slags like copper Consult our engineering team regarding your specific material characteristics

2.Q How does this system integrate with our existing magnetic separators?
A.The conveyor discharge heights magnetic drum positions are designed per standard industry layouts We provide detailed interface drawings during the proposal stage ensuring compatibility with both new existing downstream separation equipment

3.Q What is the expected operational cost per ton crushed?
A.Cost per ton depends heavily on your specific abrasiveness Typically our clients report operational costs including power wear parts routine maintenance ranging between $X$Y per metric ton based on documented case studies A detailed estimate can be provided upon analysis of your sample

4.Q What training do you provide for our operations maintenance teams?
A.Comprehensive training covering safe operation routine maintenance procedures troubleshooting guidelines is conducted during commissioning Additional digital manuals video resources are provided permanently

5.Q Are spare parts readily available given our location?
A.We maintain strategic regional warehouse inventories critical wearing components Consumable items like breaker plates liner bolts are standardized items available locally globally ensuring minimal lead times

6.Q Can the plant output different aggregate sizes simultaneously?
A Yes By incorporating multideck vibrating screens postcrushing stages the standard configuration can produce two three precisely graded aggregate fractions concurrently meeting various market specifications

7.Q What are typical payment terms delivery lead times?
A Standard commercial terms involve progress payments tied major milestones like design approval shop dispatch shipment Lead times range between weeks months depending model complexity current manufacturing schedule A firm schedule provided upon order confirmation