1. ABERTURA ACIONADA POR PAINPOINT

Managing slag byproduct is a persistent operational and financial drain. Você está enfrentando esses desafios comuns?
Altos custos de descarte: As taxas de aterro para escória não tratada estão aumentando, corroendo diretamente as margens do projeto.
Inefficient Manual Processing: Reliance on manual breaking or basic machinery leads to low throughput, altos custos trabalhistas, and inconsistent output sizing.
Unrecovered Metal Value: Valuable ferrous metal trapped within slag is lost to waste streams, representando um vazamento direto de receita.
Equipment Downtime: Standard crushers not built for abrasive slag suffer premature wear on liners and blow bars, causing frequent stoppages for maintenance.
Congestionamento do site & Logística: Stockpiled slag consumes valuable space and complicates site logistics, hindering other operations.

What if your slag handling could transform from a cost center into a source of recovered material and improved site efficiency? The solution lies in purposeengineered processing equipment.

2. VISÃO GERAL DO PRODUTO

A White Label Slag Crusher Plant is a turnkey, unbranded processing system designed specifically for the size reduction and liberation of metals from metallurgical slag (alto-forno, forno de aço, etc.). The plant is provided as a complete package, ready for your branding and integration.

Fluxo de Trabalho Operacional:
1. Alimentar & Pré-triagem: Raw slag is fed into a vibrating grizzly feeder to remove fine undersize material prior to crushing.
2. Redução de tamanho primário: A robust jaw crusher or impact breaker performs the initial crushing, breaking down large slabs of slag.
3. Libertação Metálica & Separação: The crushed material is conveyed to an electromagnetic separator which extracts liberated ferrous metal for recycling.
4. Britagem Secundária & Dimensionamento (Opcional): A cone crusher or secondary impactor further processes the material to achieve precise final product specifications.
5. Estoque: O limpo, sized aggregate is conveyed to a designated stockpile for use as a secondary raw material in construction or road base.

Escopo de aplicação: Ideal para siderúrgicas, fundições, metal recycling yards, and independent processors handling ferrous slag byproducts.
Limitações: Not designed for nonferrous slags without magnetic separation components or for primary rock mining applications with higher compressive strengths.

3. RECURSOS PRINCIPAIS

HEAVYDUTY FEEDER | Base Técnica: Reinforced grizzly bars with high stroke vibration motors | Benefício Operacional: Alças grandes, uneven slag slabs without bridging; removes fines to increase primary crusher efficiency | Impacto do ROI: Reduz o desgaste do britador em até 15% and improves overall system throughput.

ABRASIONRESISTANT CRUSHING CHAMBER | Base Técnica: Manganese steel liners & wear parts with optimal nip angles | Benefício Operacional: Withstands continuous abrasive impact, estendendo os intervalos de manutenção por 3050% over standard configurations | Impacto do ROI: Lowers costperton for wear parts and reduces downtime for liner changes.

INTEGRATED MAGNETIC SEPARATOR | Base Técnica: Selfcleaning crossbelt electromagnet with adjustable height/intensity | Benefício Operacional: Automatically extracts liberated ferrous metal continuously during operation | Impacto do ROI: Capturas 95%+ de metal recuperável, creating a new revenue stream from waste.

CENTRALIZED PLC CONTROL SYSTEM | Base Técnica: Automated process sequencing with fault diagnostics | Benefício Operacional: Enables singleoperator control of the entire plant; provides clear alerts for maintenance issues | Impacto do ROI: Reduces labor requirements and prevents minor issues from causing major breakdowns.

MODULAR PLANT DESIGN | Base Técnica: Bolttogether subassemblies on heavyduty skid bases | Benefício Operacional: Simplifies transportation and reduces onsite installation time and cost by an estimated 40% | Impacto do ROI: Faster commissioning gets your return on investment started sooner.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Basic Crusher) | White Label Slag Crusher Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Taxa de recuperação de metal | Manual picking or postcrush separation ~70% recovery rate. Integrated inline magnetic separation captures >95%. Up to ~35% more metal recovered |
| Vida útil da peça de desgaste| Standard manganese in generic crushers lasts ~40k tons in slag duty.| Liga otimizada & design yields ~60k tons per set.| ~50% longer operational life |
| Rendimento de tonelagem| Discontinuous feeding due to bridging; inconsistent feed size.| Prescreening & heavyduty feeder ensures steady, optimized feed to crusher.| Up to ~25% higher sustained throughput |
| OnSite Setup Time| Componentbased delivery requiring significant assembly.| Preassembled modules reduce field connection work.| Implantação aproximadamente 40% mais rápida |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 50 para 250 toneladas por hora (TPH).
Requisitos de energia: Total installed power typically 150kW 400kW depending on configuration; 400V/50Hz ou conforme especificado.
Especificações de materiais: Constructed from S355JR structural steel; crushing chambers lined with Mn18Cr2 or equivalent highabrasion steel.
Principais dimensões físicas (Configuração típica): Feed Hopper: 8m³; Abertura de alimentação do britador primário: 750mm x 500mm; Pegada vegetal (CxL): aprox.. 25m x 7m.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; as conexões do sistema de supressão de poeira são padrão.

6. CENÁRIOS DE APLICAÇÃO

Steel Mill OnSite Processing | Desafio: A midsized steel mill faced rising landfill costs for blast furnace slag and needed to clear storage yards. Manual processing was too slow. Solução: Implementation of a midrange white label slag crusher plant with magnetic separation at the yard perimeter. Resultados: Achieved processing of 120 TPH; eliminated landfill fees; recovered over $75k annually in scrap metal sales; created saleable aggregate.

Independent Recycling Contractor Expansion Challenge An aggregate recycler sought to diversify into industrial byproducts but required a costeffective entry solution without premium branding costs.Solution Acquisition of a base model white label plant allowing them to apply their own brand Result Enabled service contracts with two local foundries increased overall site revenue by an estimated increased asset utilization

Foundry Byproduct Management Challenge A foundry's cupola slag was being sold at minimal value as mixed waste containing recoverable metallics Solution Installation of a compact white label crushing and screening circuit focused primarily on metal liberation Result Metal recovery increased yield by concentrated aggregate product commanded higher market price improving margin on byproduct

7 CONSIDERAÇÕES COMERCIAIS

White label plants offer significant value by eliminating brand premiums Pricing is tiered based on capacity and automation level

Tier Basic Model Includes primary jaw crusher grizzly feeder magnetic separator basic belt conveyors manual controls Ideal for lower volume or entrylevel applications
Tier Pro Model Adds secondary impactor vibrating screen after magnet PLC control panel dust suppression system For operations requiring specific product sizing
Tier Custom HighCapacity Model Includes larger feeders dual crushing stages advanced screening multiple magnets full automation package For highvolume dedicated processing facilities

Optional Features Radial stacker conveyor additional screening decks metal baler press advanced dust collection
Service Packages are available separately including commissioning spare parts kits preventive maintenance plans extended warranty
Financing Options can be facilitated through equipment financing partners offering lease or loan structures typically ranging from months

8 Perguntas frequentes

What feedstock size can the plant accept
The primary crusher is configured based on your typical slab size Common feed openings accept material up tomms in dimension

How pure is the recovered metal
Field data shows the integrated crossbelt magnet typically extracts ferrous material at purity facilitating direct sale to scrap yards without further processing

Are these plants suitable for portable skidmounted use
Yes core designs are skidmounted allowing relocation between sites with appropriate haulage equipment some models offer trailer mounting

What is the expected lead time from order to commissioning
For standard configurations lead time averages weeks factoring in manufacturing testing disassembly shipment reassembly onsite commissioning varies

Can the plant process other materials like construction demolition waste
While robust it is optimized for abrasive slags Minor configuration changes can adapt it C D waste but throughput may differ from dedicated C D equipment