1. PAINPOINT DRIVEN OPENING

Managing slag byproduct is a persistent operational bottleneck with tangible costs. Are you facing these challenges?
High Downtime for Primary Crushers: Uncrushed slag with oversized metal inclusions causes frequent jams in primary crushers, leading to hours of unplanned maintenance and lost processing time.
Inefficient Material Handling & Sorting: Manual or rudimentary separation of valuable scrap metal from aggregate is laborintensive, inconsistent, and represents a loss of recoverable revenue.
Downstream Equipment Damage: Unidentified tramp metal and uncrushable debris bypass initial processing, causing accelerated wear or catastrophic failure in conveyors, screens, and secondary crushers.
Inconsistent Feed Size for Processing: Variable slag feed results in an inconsistent product size, reducing the efficiency and quality control of your final aggregate or feedstock.

The core question for plant managers is: how can you transform a costly waste stream into a controlled, profitable material flow while protecting your core crushing circuit?

2. PRODUCT OVERVIEW

A CEMarked Slag Crusher Plant is a purposebuilt, stationary or semimobile processing system designed for the primary reduction and liberation of slag from steel mills, foundries, and metal production facilities. Its design prioritizes the handling of abrasive, heterogeneous material containing metallic inclusions.

Operational Workflow:
1. Feed & PreScreening: Runoffurnace slag is fed via loader into a robust hopper, often with a grizzly section to bypass subsize material.
2. Primary Liberation Crushing: The core crusher (typically a jaw or impact type) aggressively reduces the slag mass, breaking it apart to liberate embedded metallic components.
3. Metal Separation & Extraction: Crushed material passes over an overhead magnetic separator (suspended magnet or magnetic pulley), which automatically extracts ferrous scrap for recovery.
4. Sizing & Stockpiling: The separated aggregate fraction is conveyed to a primary stockpile or directly to a secondary screening circuit for further grading.

Application Scope: Ideal for integrated steel plants, standalone slag processing yards, and aggregate producers specializing in secondary materials. Best suited for ferrous slag (BOF, EAF). Performance on nonferrous slags requires specific configuration.

Limitations: Not a substitute for fine grinding or tertiary crushing circuits. Feed size is limited by the primary crusher opening. Optimal operation requires material with a manageable moisture content to prevent clogging.

3. CORE FEATURES

HeavyDuty Grizzly Feeder | Technical Basis: Prescreening & regulated feed | Operational Benefit: Removes fines prior to crushing and ensures a consistent, controlled feed rate to the crusher chamber | ROI Impact: Increases crusher throughput by up to 15% and reduces wear on crusher liners

Reinforced Jaw Crusher Chamber | Technical Basis: High manganese steel liners & optimized nip angle | Operational Benefit: Withstands extreme abrasion and shock loads from uncrushable metals; hydraulic toggle adjustment allows quick setting changes | ROI Impact: Reduces liner replacement frequency by ~30% versus standard configurations

Integrated Overband Magnetic Separator | Technical Basis: Permanent magnet or electromagnetic circuit mounted over discharge conveyor | Operational Benefit: Automatically extracts liberated ferrous scrap continuously during operation without stopping the process flow | ROI Impact: Captures 95%+ of recoverable metal, creating a direct revenue stream from waste

Centralized Greasing & Hydraulic System | Technical Basis: Singlepoint lubrication lines for key bearings and hydraulic controls for adjustment/clearing | Operational Benefit: Enables safe, routine maintenance in under 30 minutes; allows operators to clear blockages remotely | ROI Impact: Cuts planned maintenance time by half and minimizes personnel exposure to equipment internals

CE Certified Safety Guards & Access Platforms | Technical Basis: Full compliance with EU Machinery Directive 2006/42/EC | Operational Benefit: Provides safe, compliant access for inspection and maintenance; interlocks prevent operation during servicing | ROI Impact: Mitigates risk of regulatory noncompliance fines and reduces workplace incident potential

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Basic Crushing) | CEMarked Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Metal Recovery Rate | Manual picking postcrushing (~7080%) | Continuous automated extraction during process (>95%)| +20% Recovery Efficiency |
| Crusher Downtime due to Tramp Metal| 812 hours per month for clearing/repair| Less than 2 hours per month with hydraulic clearing| ~80% Reduction in Unplanned Stops |
| Liner Life in Abrasive Service| Approx. 60,000 tonnes per set| Approx. 85,000 tonnes per set (reinforced)| ~40% Longer Service Life |
| Process Consistency (Feed Control)| Manual loader feeding (variable)| Grizzly feeder + regulated flow (consistent)| Throughput stability improved by ~25% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 to 400 tonnes per hour.
Primary Crusher Options: Jaw Crusher (models from 750x500mm to 1200x1000mm) or Impact Crusher with hydraulic adjustment.
Power Requirements: Total installed power typically between 90 kW 250 kW, dependent on configuration (400V/50Hz standard).
Key Material Specifications:
Crusher Liners: AR400 / Hardox steel or premium manganese steel.
Conveyor Belting: Minimum EP400/3 with abrasionresistant covers.
Structural Frame: Heavyduty welded sections from S355JR steel.
Physical Dimensions (Typical Setup): Approximate footprint of 20m L x 8m W x 7m H. Designed for flat concrete foundation.
Environmental Operating Range: Designed for ambient temperatures from 10°C to +45°C. Dust suppression spray bars are fitted as standard at transfer points.

6. APPLICATION SCENARIOS

Integrated Steel Mill – BOF Slag Processing | Challenge: A European mill faced daily downtime in its aggregate plant due to oversized slag chunks containing "skulls" jamming their existing crusher. Manual metal recovery was inefficient.| Solution: Installation of a CEMarked Slag Crusher Plant with a heavyduty jaw crusher and powerful overband magnet at the slag tipping point.| Results: Unplanned crusher stoppages were eliminated. The plant now recovers an additional €45,000 annually in ferrous scrap sales and produces consistent 150mm aggregate for internal roadbase use.

Independent Slag Processing Contractor | Challenge: A contractor needed to process varying stockpiles of EAF slag at multiple sites but required compliance with EU site safety regulations.| Solution: A semimobile skidmounted CEMarked Slag Crusher Plant was selected.| Results:The unit can be relocated between sites within days while maintaining full CE compliance at each location. Contractual penalties related to noncompliant equipment were avoided.

7. COMMERCIAL CONSIDERATIONS

Our CEMarked Slag Crusher Plants are offered in three primary tiers:
Standard Duty Plant: For lowervolume operations (<100tph). Includes core jaw crusher,magnet,and basic discharge conveyor.
HeavyDuty Plant: For highvolume steel mills (>200tph). Features reinforced impactor option,vibrating grizzly feeder,and multiple magnetic separation stages.
SemiMobile Skid Plant: For multisite contractors.All core components mounted on heavyduty skidsfor transportability.

Optional features include:

• Secondary screening unit
• Advanced dust suppression system
• Metal fragmentizer attachment
• Remote monitoring telematics package

We offer comprehensive service packages including scheduled maintenance plans,lifetime technical support,and guaranteed parts availability within48 hoursfor critical components.Financing options include capital purchase,tailored leasing agreements,and rentaltoown structures.

8.FAQ

Q1.Is this plant compatible with our existing conveyor system?
A1.Field data shows integration is straightforward.The plant's discharge heightand conveyor speed are engineeredto match standard downstream systems.We require your existing specificationsfor confirmation.

Q2.What is the expected operational cost per tonne processed?
A2.Based on configured powerand typical wear part consumption,costs range between €0 .80and €1 .50per tonne.This includes power,lubricants,and liner wear but excludes labor.Scrap metal revenue typically offsetsa significant portionof this cost.

Q3.How does CE marking affect installation timelines?
A3.CE marking signifies all safetydocumentationis preassembled.This can reduce commissioning timeby approximately15%as no retrofittingof guardsor safety systemsis required.Compliance documentationis provided upfrontfor site authority review.

Q4.Can it handle wetor sticky slag?
A4.The standard configuration performs optimallywith material moisture content below10%.For higher moisture,a hydraulic jaw crushera combinedwith specific hopper designsare availableas options toprevent bridgingand clogging

Q5.What warrantyis providedon major components?
A5.We providea24monthwarrantyon structural componentsanda12monthwarrantyon mechanicaland electricalpartsagainst manufacturing defects.Wear parts(crusher liners)are coveredunder aseparateperformancebased warrantyterm

Q6.Are operator trainingand manuals included?
A6.Comprehensive documentationincludingCE Declarationsof Conformityinstallation manualsand parts listsare standard.We provideonsite operational trainingfor your crewover two daysat commissioning

Q7.Do you offer performance guarantees?
A7.We contractually guaranteecapacity throughputwithin5%of specified ratingmetal recovery ratesabove95%for liberated ferrous materialand thatthe plantwill meetall declaredCE safety standards