Slag Crusher Plant Vendor Datasheet
Slag Crusher Plant Vendor Datasheet: Engineering Reference for Procurement and Installation
1. آپريشنل چئلينج: Why Standard Crushing Equipment Fails in Slag Processing
هر 10,000 tons of steel production generates approximately 1,500–2,000 tons of slag. Your plant's profitability depends on how efficiently you convert this byproduct into reusable aggregates, metal recovery feedstock, or cementgrade material. اڃان تائين, plant managers consistently face the same bottlenecks:
- Premature wear and tear: Standard jaw and cone crushers experience 40–60% faster component degradation when processing slag due to its abrasive mineralogy (containing free lime, magnesia, and metallic iron particles). Replacement of wear liners on a conventional crusher processing slag can cost $18,000–$45,000 per cycle, with downtime of 3–5 days per changeout.
- Metal contamination damage: Tramp metal (اسڪريپ اسٽيل, rebar fragments) entering the crushing chamber causes catastrophic structural failure. Industry data indicates unplanned downtime from metalrelated damage averages 12–18 hours per incident, costing $8,000–$15,000 per hour in lost production.
- Moisture and temperature variability: Slag feed material can arrive at 200–400°C from the cooling pit, with moisture content fluctuating between 3% ۽ 12%. Standard crushers experience packing, بند ڪرڻ, and thermal stress under these conditions.
- غير مطابقت واري پيداوار جي درجه بندي: Meeting strict specifications for road base (0-40 ملي ميٽر), اسفالٽ جو مجموعو (0–14mm), or cement feed (0-5 ملي ميٽر) requires precise control that conventional singlestage crushing cannot deliver.
The question is not whether you need slag processing equipment—it is whether your current vendor understands the specific metallurgical, حرارتي, and abrasive demands of slag. This datasheet provides the engineering baseline for evaluating a dedicated slag crusher plant solution.
2. پيداوار جو جائزو: The Dedicated Slag Crusher Plant System
A slag crusher plant is an integrated, multistage processing system engineered specifically for the reduction of ferrous and nonferrous slag into saleable aggregates and recoverable metallic fractions. Unlike retrofit solutions, this dedicated plant addresses the unique physical properties of slag: high abrasivity (Mohs hardness 6–7), elevated temperature at feed point, and the presence of ductile metallic contaminants.
آپريشنل ڪم فلو (5Stage Process)
1. کاڌ خوراڪ & وائبريٽنگ فيڊر: Accepts slag from dump trucks or conveyor discharge. The heavyduty grizzly feeder (with 50–75mm gap) scalps oversized material and removes fines, while the hopper liner is fabricated from 20mm Hardox 450 to resist impact abrasion.
2. پرائمري جبڑے کولہو (SlagSpecific Configuration): A reinforced jaw crusher with a 1.5x safety factor on the toggle plate mechanism. The crushing chamber is designed with a wider feed opening (typically 900×750mm) to accept slag chunks up to 600mm. The eccentric shaft is forged from 40CrNiMoA alloy steel, and the fixed jaw plate uses a waveshaped profile to improve interparticle crushing of brittle slag.
3. مقناطيسي علحدگي (پرائمري & ثانوي): Overband magnetic separators (suspension type, 1200mm پٽي ويڪر) remove ferrous metals after primary crushing. This step is critical—it recovers 90–95% of the metallic iron content (worth $250–$350 per ton as scrap) and protects downstream crushers from damage.
4. ثانوي مخروط کولہو (HeavyDuty): A springrelease cone crusher with a special crushing cavity (ٿلهو, وچولي, يا ٺيڪ) matched to the target product size. The main shaft is supported by a largediameter spherical bearing to absorb shock loads from residual metal. Hydraulic adjustment allows closedside setting (سي ايس ايس) changes from 25mm down to 6mm without stopping the plant.
5. چمڪندڙ اسڪرين & Product Conveyors: هڪ ٽريپل ڊيڪ مائل اسڪرين (مثال, 2YK2460) classifies material into 0–5mm, 5–15mm, 15–25mm, and 25–40mm fractions. Each product stream is conveyed to dedicated stockpiles or directly to downstream processes (ball mill feed, بيچنگ پلانٽ, وغيره).
ايپليڪيشن جو دائرو ۽ حدون
| Applicable Feed Materials | حدون |
|||
| ڌماڪي واري فرنس سليگ (هوائي ٿڌو, granulated) | Not suitable for wet slag with >15% moisture without predrying |
| Steelmaking slag (بي او ايف, اي ايف, ايل ايف) | Feed temperature must be below 80°C for standard belt conveyors |
| Ferroalloy slag (FeCr, FeMn, FeSi) | وڌ ۾ وڌ فيڊ سائيز: 600ايم ايم (larger requires primary breaking) |
| Copper/nickel smelter slag | Not designed for radioactive or hazardous waste materials |
| Incinerator bottom ash (IBA) | Throughput reduces by 30–40% when processing highclaycontent feed |
3. بنيادي خاصيتون: Engineering Specifications and Operational Benefits
Reinforced Welded Frame Construction | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي)بهتر دٻاء جي ورڇ | آپريشنل فائدا: Frame deflection reduced to <0.5mm under full load, ensuring bearing alignment and extended component life | ROI اثر: 15–20% longer service life compared to standard fabricated frames, سرمائي جي بدلي جي تعدد کي گھٽائڻ
The main crusher frame is fabricated from Q345B lowalloy steel plates (20–30mm thickness), ويلڊنگ کان پوء دٻاء. FEA analysis confirms that stress concentrations at the bearing housing and toggle seat areas are maintained below 80 MPa—well within the material's fatigue limit. This design prevents the frame cracking commonly observed in modified standard crushers used for slag.
SlagSpecific Manganese Steel Wear Parts | ٽيڪنيڪل بنياد: Highworkhardening austenitic manganese steel (Mn13Cr2 or Mn18Cr2) | آپريشنل فائدا: Wear life of 4,000–6,000 hours on jaw plates and 3,000–4,500 hours on cone liners when processing typical blast furnace slag | ROI اثر: Replacement wear parts cost $12,000–$28,000 per set; extended life reduces annual wear part expenditure by 25–35%
Standard Mn18Cr2 (18% مينگنيز, 2% ڪروميم) is specified for the primary jaw. For the secondary cone crusher, we recommend Mn13Cr2 with a thicker crosssection (up to 120mm at the feed point) to withstand the impact of residual metal. The wear parts are cast using the Vmethod (vacuum sealed) عمل, ensuring uniform hardness of 170–220 HB in the ascast condition, workhardening to 450–550 HB on the working surface.
هائيڊولڪ ٽراپ رليز سسٽم | ٽيڪنيڪل بنياد: Accumulatorcharged hydraulic cylinders with 40mm stroke | آپريشنل فائدا: Passes uncrushable metal (up to 150mm diameter) through the chamber in 3–5 seconds, automatically resetting to the original CSS | ROI اثر: ختم ڪري ٿو 90% of unplanned downtime events; typical payback period of 6–9 months based on avoided repair costs
The hydraulic system operates at 120–160 bar and is equipped with a nitrogen accumulator that absorbs the shock of metal entry. Sensors monitor cylinder position; if the CSS does not return to setpoint within 10 سيڪنڊ, the system triggers an alarm and stops the feed belt, preventing secondary damage.
DualStage Magnetic Separation with Metal Recovery Conveyor | ٽيڪنيڪل بنياد: نيوڊيميم (NdFeB) permanent magnets with 12,000 Gauss surface field strength | آپريشنل فائدا: بحال ڪري ٿو 95% فيرس دھاتن جو >10mm from the slag stream; recovered metal is conveyed to a dedicated bunker | ROI اثر: Metal recovery revenue of $8–$15 per ton of slag processed (at current scrap prices), representing 10–15% of total plant revenue
The primary overband magnet is positioned at a 45degree angle over the main discharge conveyor, while the secondary magnetic head pulley (at the screen feed conveyor) captures residual fines. The metal recovery rate is verified through periodic sampling: فيلڊ ڊيٽا کان 12 installations shows average recovery of 38–52 kg of metal per ton of BOF slag.
Dust Suppression and Sealing System | ٽيڪنيڪل بنياد: Multistage water spray nozzles (atomized, 50–100 micron droplets) at transfer points and crusher inlets | آپريشنل فائدا: Airborne dust concentration at the plant boundary maintained below 2 mg/m³ (meets EU and US EPA standards) | ROI اثر: Avoids regulatory fines of $10,000–$50,000 per violation; improves operator working conditions, reducing staff turnover
The system includes a highpressure pump (70 بار), a ring main around the crusher house, and ultrasonic sensors that activate sprays only when material flow is detected—reducing water consumption to 0.5–1.0 m³ per hour. For coldclimate installations, an optional airatomizing system (using compressed air instead of water) is available.
PLCBased Automated Control with Remote Monitoring | ٽيڪنيڪل بنياد: Siemens S71200 PLC with HMI touchscreen (10انچ) and optional SCADA integration | آپريشنل فائدا: Singleoperator supervision of the entire plant; automatic start/stop sequencing; realtime display of motor currents, برداشت جي درجه حرارت, and vibration levels | ROI اثر: Labor cost reduction of 2–3 operators per shift; predictive maintenance alerts reduce repair costs by 20–25%
The control system monitors 32 analog inputs (موٽر amps, گرمي پد, دٻاءُ) ۽ 48 digital inputs (limit switches, proximity sensors). Alarm thresholds are configurable; the system logs all events with timestamps for ISO 9001 compliance audits.
ماڊلر اسڪيڊ مائونٽ ٿيل ڊيزائن | ٽيڪنيڪل بنياد: ISO containercompatible modules (20ft and 40ft footprint) | آپريشنل فائدا: Plant relocation achievable in 5–7 days using standard flatbed trailers; foundation work reduced to simple concrete pads | ROI اثر: Relocation costs of $15,000–$25,000 versus $80,000–$120,000 for a fixed plant; enables contract crushing at multiple sites
Each module (کولہو يونٽ, اسڪرين يونٽ, conveyor system) is prewired and prepiped at the factory. Site installation requires only: (1) concrete pad preparation (2–3 days), (2) module placement and alignment (1–2 days), (3) electrical connection to the site transformer (1 ڏينهن), ۽ (4) commissioning and test run (2 ڏينهن).
4. مقابلي جا فائدا: ڪارڪردگي جو مقابلو
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (Modified Aggregate Crusher) | Dedicated Slag Crusher Plant Solution | فائدو (% سڌارو) |
|||||
| Wear part service life (جبڑے جي پليٽ) | 1,800–2,500 hours | 4,000–6,000 hours | 60–140% longer |
| اڻ رٿيل بند وقت (metalrelated) | 12–18 hours/month | 2–4 hours/month | 75–85% reduction |
| ڌاتو جي وصولي جي شرح | 60-70% (واحد مقناطيس, no dedicated recovery) | 90-95% (dualstage with recovery conveyor) | 30–40% higher recovery |
| پيداوار جي درجه بندي جي تسلسل (P90 within spec) | 75–80% of production runs | 95–98% of production runs | 20–25% improvement |
| Throughput efficiency (tons/hour per kW) | 0.8–1.2 t/h/kW | 1.5–2.0 t/h/kW | 25–65% higher efficiency |
| تبديليءَ جو وقت (لباس جو حصو متبادل) | 16- 24 ڪلاڪ (crane + دستي ڪم) | 8- 12 ڪلاڪ (hydraulic tools + guided alignment) | 50% تيز |
| سالياني سار سنڀال جي قيمت (جيئن % سامان جي قيمت) | 8-12 سيڪڙو | 5-7 سيڪڙو | 35–45% lower |
| Dust emission level (plant boundary) | 5–10 mg/m³ (often noncompliant) | <2 mg/m³ (مطابق) | 60–80% lower |
Data compiled from field studies of 15 slag processing installations (2019-2024) and manufacturer test reports.
5. ٽيڪنيڪل وضاحتون: معياري ترتيب (Model SCP200)
Capacity and Performance Ratings
| پيرا ميٽر | قدر | Notes |
||||
| Rated throughput | 150–200 t/h | Based on feed density of 1.6–2.0 t/m³, feed size ≤600mm |
| وڌ ۾ وڌ فيڊ سائيز | 600ايم ايم (ڪنڊ ڊگھائي) | Larger requires primary breaking or grizzly modification |
| پيداوار جي ماپ جي حد | 0-5 ملي ميٽر, 5–15mm, 15–25mm, 25-40 ملي ميٽر | Adjustable via screen mesh selection and crusher CSS |
| گھٽتائي جو تناسب (پرائمري) | 4:1 جي طرف 6:1 | Jaw crusher CSS: 75–150mm |
| گھٽتائي جو تناسب (ثانوي) | 3:1 جي طرف 5:1 | Cone crusher CSS: 6–25mm |
| Metal recovery capacity | 15–30 t/h of ferrous scrap | Based on 10–15% metal content in feed |
بجلي جي گهرج
| جزو | انسٽال ٿيل پاور (ڪلواٽ) | Operating Power (ڪلواٽ) | Voltage/Frequency |
|||||
| پرائمري جبڑے کولہو (PE750×1060) | 110 | 75-95 | 380V/50Hz يا 460V/60Hz |
| ثانوي مخروط کولہو (PYB1750) | 160 | 110–140 | 380V/50Hz يا 460V/60Hz |
| Vibrating screen (2YK2460) | 30 | 22–26 | 380V/50Hz يا 460V/60Hz |
| مقناطيسي جدا ڪندڙ (2 يونٽ) | 7.5 هر هڪ | 5.5 هر هڪ | 380V/50Hz يا 460V/60Hz |
| ڪنويرز (6 يونٽ, total length 85m) | 45 (ڪل) | 30–38 | 380V/50Hz يا 460V/60Hz |
| Dust suppression pump | 11 | 7.5 | 380V/50Hz يا 460V/60Hz |
| ڪل نصب طاقت | ~370 kW | ~250–320 kW | — |
مواد جي وضاحت
| جزو | مواد | Hardness/Strength | Notes |
|||||
| جبلن جي پليٽ (مقرر & movable) | Mn18Cr2 austenitic manganese steel | 170–220 HB (ascast), workhardens to 450–550 HB | Reversible design for extended life |
| مخروطي لينر (چادر & مقدر) | Mn13Cr2 with 120mm max thickness | 170–220 HB (ascast) | Thicker at feed zone |
| فريم & main structure | Q345B lowalloy steel, 20–30mm plate | Yield strength: 345 ايم پي اي | Stressrelieved after welding |
| ڍڳي & ڪپڙا لائينر | هارڊوڪس 450 (يا برابر) | 425–475 HB | 20mm ٿولهه, bolton replaceable |
| شافٽ (سنسڪرت & مکيه) | 40CrNiMoA alloy steel | 280–320 HB (گرميءَ جو علاج) | جڙيل, then precision machined |
| بيئرنگ (کولہو) | گولي وارو رولر بيرنگ (SKF/FAG) | C4 clearance | Greaselubricated, automatic lubrication optional |
Physical Dimensions and Weight
| ماڊل | ڊگھائي (م) | ويڪر (م) | اوچائي (م) | وزن (ٽين) |
||||||
| کاڌ خوراڪ + گرزلي فيڊر | 6.5 | 3.2 | 3.8 | 12.5 |
| Primary jaw crusher module | 5.8 | 3.5 | 4.2 | 28.0 |
| Secondary cone crusher module | 5.2 | 3.8 | 5.5 | 32.5 |
| Screen module (ٽرپل ڊيڪ) | 7.0 | 3.0 | 4.5 | 15.0 |
| Conveyor system (ڪل) | 85 (لڪير) | 1.2 (پٽي جي چوٽي) | — | 18.5 |
| ڪل ٻوٽي جو نشان | ~45m × 25m | — | — | ~110 tons (صرف سامان) |
ماحولياتي آپريٽنگ رينج
| پيرا ميٽر | آپريٽنگ رينج | Notes |
||||
| ماحول جي درجه حرارت | 20°C کان +50°C | Optional coldweather package (هيٽر, special lubricants) هيٺ 10 ° C |
| Feed material temperature | ≤80°C at crusher inlet | Higher temperatures require cooling conveyor or water spray |
| نسبتي نمي | 5-95% (غير ڪنڊينسنگ) | Electrical enclosures rated IP54 minimum |
| اوچائي | Up to 2,000m above sea level | Derating of 1% per 100m above 1,000m for motor power |
| شور جي سطح (at 1m from equipment) | ≤85 ڊي بي(اي) | Meets EU Machinery Directive 2006/42/EC |
