Slag Crusher Plant Vendor Datasheet
Slag Crusher Plant Vendor Datasheet: Engineering Reference for Procurement and Installation
1. Thử thách hoạt động: Why Standard Crushing Equipment Fails in Slag Processing
Mọi 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. Chưa, 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 (scrap steel, mảnh cốt thép) 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% Và 12%. Standard crushers experience packing, tắc nghẽn, and thermal stress under these conditions.
- Phân loại sản phẩm không nhất quán: Meeting strict specifications for road base (0–40mm), cốt liệu nhựa đường (0–14mm), or cement feed (0–5mm) 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, nhiệt, and abrasive demands of slag. This datasheet provides the engineering baseline for evaluating a dedicated slag crusher plant solution.
2. Tổng quan về sản phẩm: 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.
Quy trình hoạt động (5Stage Process)
1. Phễu thức ăn & Bộ nạp rung: 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. Máy nghiền hàm sơ cấp (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. Tách từ (Sơ đẳng & Sơ trung): Overband magnetic separators (suspension type, 1200chiều rộng vành đai mm) 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. Máy nghiền hình nón thứ cấp (nhiệm vụ nặng nề): A springrelease cone crusher with a special crushing cavity (thô, trung bình, or fine) 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 (CSS) changes from 25mm down to 6mm without stopping the plant.
5. Màn hình rung & Product Conveyors: A tripledeck inclined screen (ví dụ., 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, trạm trộn, vân vân.).
Phạm vi ứng dụng và hạn chế
| Applicable Feed Materials | Hạn chế |
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| Xỉ lò cao (aircooled, dạng hạt) | Not suitable for wet slag with >15% moisture without predrying |
| Steelmaking slag (BOF, EAF, LF) | Feed temperature must be below 80°C for standard belt conveyors |
| Ferroalloy slag (FeCr, FeMn, FeSi) | Kích thước nguồn cấp dữ liệu tối đa: 600mm (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. Tính năng cốt lõi: Engineering Specifications and Operational Benefits
Reinforced Welded Frame Construction | Cơ sở kỹ thuật: Phân tích phần tử hữu hạn (FEA)phân phối ứng suất tối ưu | Lợi ích hoạt động: Frame deflection reduced to <0.5mm under full load, ensuring bearing alignment and extended component life | Tác động ROI: 15–20% longer service life compared to standard fabricated frames, giảm tần suất thay thế vốn
The main crusher frame is fabricated from Q345B lowalloy steel plates (20–30mm thickness), giảm căng thẳng sau khi hàn. 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 | Cơ sở kỹ thuật: Highworkhardening austenitic manganese steel (Mn13Cr2 or Mn18Cr2) | Lợi ích hoạt động: 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 | Tác động ROI: Replacement wear parts cost $12,000–$28,000 per set; extended life reduces annual wear part expenditure by 25–35%
Standard Mn18Cr2 (18% mangan, 2% crom) 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) quá trình, ensuring uniform hardness of 170–220 HB in the ascast condition, workhardening to 450–550 HB on the working surface.
Hệ thống phát hành Tramp thủy lực | Cơ sở kỹ thuật: Accumulatorcharged hydraulic cylinders with 40mm stroke | Lợi ích hoạt động: Passes uncrushable metal (up to 150mm diameter) through the chamber in 3–5 seconds, automatically resetting to the original CSS | Tác động ROI: Loại bỏ 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 giây, the system triggers an alarm and stops the feed belt, preventing secondary damage.
DualStage Magnetic Separation with Metal Recovery Conveyor | Cơ sở kỹ thuật: Neodymium (NdFeB) permanent magnets with 12,000 Gauss surface field strength | Lợi ích hoạt động: Phục hồi 95% of ferrous metals >10mm from the slag stream; recovered metal is conveyed to a dedicated bunker | Tác động ROI: 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: dữ liệu trường từ 12 installations shows average recovery of 38–52 kg of metal per ton of BOF slag.
Dust Suppression and Sealing System | Cơ sở kỹ thuật: Multistage water spray nozzles (atomized, 50–100 micron droplets) at transfer points and crusher inlets | Lợi ích hoạt động: Airborne dust concentration at the plant boundary maintained below 2 mg/m³ (meets EU and US EPA standards) | Tác động ROI: Avoids regulatory fines of $10,000–$50,000 per violation; improves operator working conditions, reducing staff turnover
The system includes a highpressure pump (70 thanh), 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 | Cơ sở kỹ thuật: Siemens S71200 PLC with HMI touchscreen (10inch) and optional SCADA integration | Lợi ích hoạt động: Singleoperator supervision of the entire plant; automatic start/stop sequencing; realtime display of motor currents, nhiệt độ mang, và mức độ rung | Tác động ROI: 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 (amp động cơ, nhiệt độ, áp lực ) Và 48 digital inputs (limit switches, proximity sensors). Alarm thresholds are configurable; the system logs all events with timestamps for ISO 9001 compliance audits.
Thiết kế kiểu mô-đun SkidMounted | Cơ sở kỹ thuật: ISO containercompatible modules (20ft and 40ft footprint) | Lợi ích hoạt động: Plant relocation achievable in 5–7 days using standard flatbed trailers; foundation work reduced to simple concrete pads | Tác động ROI: Relocation costs of $15,000–$25,000 versus $80,000–$120,000 for a fixed plant; enables contract crushing at multiple sites
Each module (đơn vị máy nghiền, đơn vị màn hình, 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 ngày), Và (4) commissioning and test run (2 ngày).
4. Lợi thế cạnh tranh: So sánh hiệu suất
| Chỉ số hiệu suất | Tiêu chuẩn ngành (Modified Aggregate Crusher) | Giải pháp nhà máy nghiền xỉ chuyên dụng | Lợi thế (% Sự cải tiến) |
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| Wear part service life (tấm hàm) | 1,800–2,500 hours | 4,000–6.000 giờ | 60–140% longer |
| Thời gian ngừng hoạt động ngoài kế hoạch (metalrelated) | 12–18 hours/month | 2–4 hours/month | 75–85% reduction |
| Tỷ lệ thu hồi kim loại | 60–70% (single magnet, no dedicated recovery) | 90–95% (dualstage with recovery conveyor) | 30–40% higher recovery |
| Product gradation consistency (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 |
| Thời gian chuyển đổi (thay thế một phần) | 16–24 giờ (crane + lao động chân tay) | 8–12 giờ (hydraulic tools + guided alignment) | 50% nhanh hơn |
| Chi phí bảo trì hàng năm (BẰNG % giá trị thiết bị) | 8–12% | 5–7% | 35–45% lower |
| Dust emission level (plant boundary) | 5–10 mg/m³ (often noncompliant) | <2 mg/m³ (tuân thủ) | 60–80% lower |
Data compiled from field studies of 15 slag processing installations (2019–2024) and manufacturer test reports.
5. Thông số kỹ thuật: Cấu hình tiêu chuẩn (Model SCP200)
Xếp hạng năng lực và hiệu suất
| tham số | Giá trị | Ghi chú |
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| Rated throughput | 150–200 t/h | Based on feed density of 1.6–2.0 t/m³, feed size ≤600mm |
| Kích thước nguồn cấp dữ liệu tối đa | 600mm (chiều dài cạnh) | Larger requires primary breaking or grizzly modification |
| Phạm vi kích thước sản phẩm | 0–5mm, 5–15mm, 15–25mm, 25–40mm | Adjustable via screen mesh selection and crusher CSS |
| Tỷ lệ giảm (sơ đẳng) | 4:1 ĐẾN 6:1 | Jaw crusher CSS: 75–150mm |
| Tỷ lệ giảm (sơ trung) | 3:1 ĐẾN 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 |
Yêu cầu về nguồn điện
| Component | Nguồn điện cài đặt (kW) | Operating Power (kW) | Voltage/Frequency |
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| Máy nghiền hàm sơ cấp (PE750×1060) | 110 | 75–95 | 380V/50Hz hoặc 460V/60Hz |
| Secondary cone crusher (PYB1750) | 160 | 110–140 | 380V/50Hz hoặc 460V/60Hz |
| Màn hình rung (2YK2460) | 30 | 22–26 | 380V/50Hz hoặc 460V/60Hz |
| Máy tách từ (2 đơn vị) | 7.5 mỗi | 5.5 mỗi | 380V/50Hz hoặc 460V/60Hz |
| Băng tải (6 đơn vị, total length 85m) | 45 (tổng cộng) | 30–38 | 380V/50Hz hoặc 460V/60Hz |
| Dust suppression pump | 11 | 7.5 | 380V/50Hz hoặc 460V/60Hz |
| Tổng công suất lắp đặt | ~370 kW | ~250–320 kW | — |
Thông số vật liệu
| Component | Vật liệu | Hardness/Strength | Ghi chú |
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| Tấm hàm (đã sửa & có thể di chuyển được) | Mn18Cr2 austenitic manganese steel | 170–220 HB (ascast), workhardens to 450–550 HB | Reversible design for extended life |
| lót hình nón (áo choàng & lõm) | Mn13Cr2 with 120mm max thickness | 170–220 HB (ascast) | Thicker at feed zone |
| Khung & main structure | Q345B lowalloy steel, 20–30mm plate | Yield strength: 345 MPa | Stressrelieved after welding |
| Phễu & chute liners | Hardox 450 (hoặc tương đương) | 425–475 HB | 20độ dày mm, bolton replaceable |
| Trục (lập dị & chủ yếu) | 40CrNiMoA alloy steel | 280–320 HB (được xử lý nhiệt) | Giả mạo, then precision machined |
| Vòng bi (máy nghiền) | Vòng bi lăn hình cầu (SKF/FAG) | C4 clearance | Greaselubricated, automatic lubrication optional |
Physical Dimensions and Weight
| mô-đun | Chiều dài (tôi) | Chiều rộng (tôi) | Chiều cao (tôi) | Cân nặng (tấn) |
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| Phễu thức ăn + máng ăn hoa râm | 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 (ba tầng) | 7.0 | 3.0 | 4.5 | 15.0 |
| Conveyor system (tổng cộng) | 85 (tuyến tính) | 1.2 (chiều rộng vành đai) | — | 18.5 |
| Tổng diện tích nhà máy | ~45m × 25m | — | — | ~110 tons (chỉ thiết bị) |
Phạm vi hoạt động môi trường
| tham số | Phạm vi hoạt động | Ghi chú |
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| Nhiệt độ môi trường xung quanh | 20°C đến +50°C | Gói thời tiết lạnh tùy chọn (heaters, special lubricants) dưới 10°C |
| Nhiệt độ nguyên liệu thức ăn | ≤80°C at crusher inlet | Higher temperatures require cooling conveyor or water spray |
| Độ ẩm tương đối | 5–95% (không ngưng tụ) | Electrical enclosures rated IP54 minimum |
| Độ cao | Up to 2,000m above sea level | Derating of 1% per 100m above 1,000m for motor power |
| Độ ồn (at 1m from equipment) | 85dB(MỘT) | Meets EU Machinery Directive 2006/42/EC |