1. ABERTURA ACIONADA POR PAINPOINT

Managing slag is a critical but costly bottleneck in metal production and recycling. O processamento ineficiente afeta diretamente seus resultados financeiros através do desgaste do equipamento, excessive downtime, e receitas perdidas de material não recuperado. Você está enfrentando esses desafios persistentes?

Altos custos de abrasão: A natureza abrasiva da escória degrada rapidamente os componentes padrão do britador, levando a trocas freqüentes de revestimento, excessive spare part inventories, and unscheduled maintenance stops that halt your entire processing line.
Alimentação imprevisível & Tempo de inatividade: Fluctuations in slag feed size, dureza, and moisture content cause chokeups, hammer rotor lockups, and premature bearing failures. This unpredictability makes production scheduling difficult and increases operational risk.
Redução de tamanho ineficiente & Contaminação: Inconsistent final product sizing—with too many fines or oversized chunks—compromises the value of your slag aggregate for downstream sales or internal recycling. Poor crushing can also lead to metal contamination in the finished product.
Alta operacional & Custos de energia: Crushers not engineered for this specific duty cycle often operate at suboptimal efficiency, drawing more power per ton processed and requiring higher labor input for monitoring and clearing.

A questão central para os gerentes de fábrica é esta: como você pode alcançar resultados consistentes, highvolume slag reduction with lower costperton and greater system reliability?

2. VISÃO GERAL DO PRODUTO

The sustainable slag crusher plant is a heavyduty, integrated processing system engineered specifically for the continuous reduction of metallurgical slag (alto-forno, forno de aço, cobre). Ele transforma grandes, irregular slag feed into a precisely graded aggregate for cement additive, road base material, or ballast.

Fluxo de Trabalho Operacional:
1. Recebimento Primário & Pré-triagem: Dumped or conveyed slag is initially grizzlyscreened to bypass subsize material and remove oversize tramp metal.
2. Core Size Reduction: Prescreened feed enters the primary slag crusher—typically a robust impact crusher or jaw crusher configuration—where it is fractured against hardened surfaces.
3. Recuperação de Metais (Opcional): Crushed material passes over an inline magnetic separator to extract remaining ferrous metal fragments, adding a revenue stream and purifying the aggregate.
4. Britagem Secundária & Dimensionamento Final: Material may be routed to a secondary cone or impact crusher for further refinement before being classified by a vibrating screen.
5. Estoque & Expedição: Correctly sized aggregate is conveyed to stockpiles; material de tamanho grande é recirculado de volta ao circuito.

Escopo de aplicação: Projetado para usinas siderúrgicas integradas, nonferrous smelters, pátios autônomos de processamento de escória, and largescale demolition recycling operations handling slagladen material.

Limitações: Not suitable for primary rock mining of virgin ore. Maximum feed size and throughput are determined by plant configuration; extremely highmoisture content without adequate feed management may require preprocessing.

3. RECURSOS PRINCIPAIS

Rotor para serviço pesado & Sistema de Impacto | Base Técnica: Highinertia rotor with oversized bearings and monoblock cast martensitic hammers/blow bars | Benefício Operacional: Sustains high crushing force against abrasive slag with minimal vibration; allows fullbreakage of large slabs | Impacto do ROI: Até 30% longer service intervals on wear parts reduces spare part costs and labor hours.

Ajuste Hidráulico & Limpeza | Base Técnica: Integrated hydraulic cylinders for gap setting adjustment and unblocking functions | Benefício Operacional: Operators can finetune product size ondemand and clear chamber blockages remotely in minutes without manual intervention | Impacto do ROI: Eliminates hours of downtime per blockage event; maintains consistent product spec without stopping.

Pacote de revestimento resistente à abrasão | Base Técnica: Composite liner system using varying grades of chromium carbide overlay steel in highwear zones | Benefício Operacional: Provides staged wear protection tailored to impact angles within the crushing chamber | Impacto do ROI: Aumento documentado de 4060% in liner life compared to standard manganese steel in slag applications.

Acionamento Inteligente & Sistema de controle | Base Técnica: Direct drive coupling with PLCcontrolled softstart and load monitoring sensors | Benefício Operacional: Reduces mechanical stress during startup; automated amp monitoring can adjust feed rate to prevent overloads | Impacto do ROI: Protects motor from surge damage; optimizes energy consumption per ton crushed.

Enclosed Design with Dust Suppression Ports | Base Técnica: Sealed housing with strategically placed spray nozzles compatible with dry fog or mist systems | Benefício Operacional: Significantly contains dust at point of generation, improving site air quality and operator safety | Impacto do ROI: Lowers compliance risk; reduces housekeeping costs and water usage compared to area spraying.

Modular Base Frame & Projeto de acesso | Base Técnica: Preassembled substructure with walkin/service platforms around all major components | Benefício Operacional: Simplifies foundation requirements and enables safer, faster maintenance access for inspection and component changeout | Impacto do ROI: Reduz o tempo de instalação em uma estimativa 25%; lowers longterm maintenance labor costs.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Typical Jaw/Cone) | Solução sustentável para planta de britagem de escória | Vantagem (% Melhoria) |
|||||
| Vida útil da peça (Primário) | 6090 days in severe slag duty | 120150 days under comparable conditions | +60% para +100% |
| Toneladas trituradas por kWh | Variável; sensitive to feed fluctuations | Consistent optimized draw due to load control| +15% average energy efficiency |
| Tempo médio entre falhas (Mecânico) | ~400 horas de operação | Dados de campo suportam >750 horário de funcionamento | +88% aumento de confiabilidade |
| Total Downtime for Liner Change 1624 horas 812 hours with designed access 50% tempo de inatividade |
| Consistência do Produto Final (% dentro das especificações) 8590% 9598% guaranteed +8% melhoria de rendimento |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 50 TPH acima 600 TPH for integrated hotslag handling systems.
Requisitos de energia: Motor do britador primário de 110 kW até 500 kW+; total plant connected load dependent on conveyors and auxiliaries.
Tamanho máximo de alimentação: Accepts slab feed up to 1500mm x 2000mm (sujeito ao modelo).
Faixa de tamanho do produto final: Adjustable from 40mm down to 10mm based on screen configuration.
Principais especificações de materiais:
Rotor/Bearings: Forged alloy steel rotor; spherical roller bearings with automated lubrication.
Peças de desgaste: Martensitic steel hammers/blow bars; AR400/AR500 liners.
Construção de moldura: Heavyduty rolled steel plate with vibration dampening mounts.
Dimensões Físicas (Example MidRange Plant): ~25m (eu) x 8m (C) x 7m (H). O design modular permite adaptação.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; dust sealing effective up to IP65 standards.

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Plant Slag Yard Challenge:

A major steel producer faced constant downtime from clogging in their existing crusher when processing variable blast furnace slag. Metal “tramp” packages caused significant damage during processing.

Solução:

Implementation of a turnkey sustainable slag crusher plant featuring an impact crusher with hydraulic clearing cylinders followed by a highstrength overhead magnetic separator.

Resultados:

Blockages were cleared in under 10 minutes versus several hours previously. The magnetic system recovered an additional 23% ferrous metal by weight from the stream. Overall plant availability increased by an estimated 22%, achieving target throughput consistently.

Copper Smelter Aggregate Production Challenge:

A smelter needed to process granulated copper slag into a fine aggregate for sale but struggled with excessive fines generation (<3milímetros) using their cone crushers, reducing product value.

Solução:

A tailored twostage sustainable slag crushing circuit using primary jaw crushing followed by specialized secondary grinding via a vertical shaft impactor configured for shaping rather than pure fracturing.

Resultados:

Production of the premium 10mm+3mm aggregate fraction increased by over 35%. Fines generation was reduced below target thresholds significantly increasing overall revenue per ton processed while meeting strict chemical composition specifications

7 CONSIDERAÇÕES COMERCIAIS

Sustainable Slag Crusher Plants are offered as modular solutions scalable across three primary tiers:

1. Unidade de serviço padrão
2 HighCapacity Integrated Plant
3 Custom Hot Slag Handling System

Pricing reflects engineering scope capacity level automation integration

Optional features that affect capital cost include advanced metal detection systems automated greasing systems premium ceramic composite wear liners remote monitoring telematics packages

Service packages are structured as follows:

Bronze Package
Silver Comprehensive Support Agreement
Gold Full Performance Contract

Financing options are available including equipment leasing capital expenditure loans payforperformance models where payments are partially tied verified throughput availability metrics

8 Perguntas frequentes

Q What existing infrastructure is required integrate this plant?
A The plant requires stable prepared foundation adequate electrical supply connection points incoming feed conveyor discharge conveyor system Basic civil engineering drawings provided facilitate integration

Q How does this solution handle wet sticky slag?
A While designed optimal performance moderately dry material several configurations available These include cascade feed systems reduce packing optional shaft heaters prevent moisture buildup critical areas Specific recommendations require analysis your feedstock

P Qual é o cronograma típico de comissionamento da instalação?
A For modular midrange plant typical timeline weeks site preparation weeks mechanical erection weeks electrical instrumentation connection weeks commissioning operator training Timeline varies based site conditions complexity

Q Are wear parts readily available interchangeable other brands?
A Wear parts engineered specific geometry metallurgy ensure designed performance longevity While not interchangeable generic brands our global distributor network maintains regional stock critical components guarantee ≤48hr shipment most locations

Q Can automation system interface existing SCADA?
A Yes The PLC control system standard Modbus TCP/IP OPC UA protocols allowing seamless data exchange most modern industrial control systems provide analog digital I/O hardwired connection required