1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
High Downtime for Primary Crushers: Abrasive slag causes premature wear on jaw plates and mantles, leading to frequent maintenance stops that halt your entire processing line.
Inefficient Material Handling: Oversized, irregular slag chunks from cooling beds jam feeders and conveyors, creating manual intervention points and safety hazards.
Uncontrolled Fines Generation: Using the wrong crushing technology can produce excessive, lowvalue fines instead of the optimally sized aggregate your customers demand.
High Total Cost of Ownership: The combined expense of premature part replacement, unscheduled downtime, and energyinefficient processing directly erodes profit margins from your slag byproduct.

The central question is: how do you reduce this operational friction and transform slag from a disposal headache into a consistent revenue stream? The answer lies in selecting equipment engineered specifically for the task.

2. PRODUCT OVERVIEW

The [Manufacturer Name] Slag Crusher Plant is a heavyduty, stationary or semimobile processing system designed for the primary and secondary reduction of aircooled blast furnace (BF) slag or steel slag. It is not intended for molten slag or materials with high metal content without prior separation.

The operational workflow is engineered for continuity:
1. Feed & PreScreening: Slag is fed via apron feeder to a scalping screen, removing fine fractions to bypass the crusher and reduce wear.
2. Primary Crushing: Oversize material is directed to a robust impact crusher or jaw crusher, selected for high reduction ratio and ability to handle occasional tramp metal.
3. Material Transfer & Secondary Crushing: Crushed material is conveyed to a secondary cone or impact crusher for precise final sizing.
4. Final Screening & Stockpiling: Material is classified on vibrating screens into commercial aggregate fractions (e.g., 05mm, 510mm, 1020mm) and conveyed to designated stockpiles.

3. CORE FEATURES

Hydraulic Adjustment System | Technical Basis: Remotecontrolled hydraulic cylinders replace mechanical shims. | Operational Benefit: Your operators can adjust the crusher gap setting in minutes versus hours, enabling quick response to product size requirements or clearing blockages. | ROI Impact: Reduces downtime for adjustments by up to 90%, increasing plant availability.

Reinforced Rotor & Wear Parts | Technical Basis: Highchrome martensitic steel castings with ceramic wear tiles in critical areas. | Operational Benefit: Withstands extreme abrasion from slag, extending service life before replacement is required. | ROI Impact: Field data shows a 4060% improvement in wear part life compared to standard manganese steel, lowering cost per ton crushed.

Integrated Metal Trap & Release | Technical Basis: Permanent magnet overband separator coupled with an automatic release system. | Operational Benefit: Continuously removes tramp metal from the crushing circuit, protecting downstream machinery from damage. | ROI Impact: Prevents costly damage to crusher internals and conveyor belts, avoiding unplanned stoppages.

Centralized Greasing & Monitoring | Technical Basis: Automated lubrication system with flow sensors connected to plant control panel. | Operational Benefit: Ensures critical bearings receive proper lubrication without manual intervention, providing early warning of potential failures. | ROI Impact: Extends bearing service life by up to 30% and prevents catastrophic bearing seizures that cause extended downtime.

Modular SkidMounted Design | Technical Basis: Preassembled crusher, feeder, and screen modules on structural steel skids. | Operational Benefit: Significantly reduces civil works and installation time on your site; facilitates future relocation if needed. | ROI Impact: Cuts installation costs by approximately 25% and allows revenue generation from crushed material weeks sooner.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Slag Crusher Plant Solution | Advantage (% improvement) |
| : | : | : | : |
| Wear Part Lifetime (Primary Stage) | Manganese Steel Jaws/Blows Bars | HighChrome Alloy with Composite Liners | +50% |
| Average Availability (Scheduled Runtime) | 8590% (due to adjustment/maintenance)| >94% (via hydraulic adjustment & monitoring) | +59% Absolute Increase |
| Energy Consumption per Ton Processed| Fixedspeed direct drives with low load efficiency| PLCcontrolled VFD drives matching power to load demand| 15% to 20% |
| Installation & Commissioning Time| 46 weeks for foundation & assembly| 1014 days for skid interconnection & alignment| 60% |

5. TECHNICAL SPECIFICATIONS

Processing Capacity: Configurable from 50 TPH to over 400 TPH of aircooled BF slag.
Primary Crusher Options: Heavyduty impact crusher (up to 1200mm feed size) or deeptoggle jaw crusher.
Power Requirement: Total installed power ranges from 150 kW to 600 kW depending on configuration.
Key Material Specifications: Hardox® liners in hoppers and chutes; ST52 structural steel for frames; SEW or Nord gearboxes; SKF/FAG bearings.
Physical Dimensions (Typical Setup): Length: ~35m; Width: ~12m; Height: ~9m (varies per model).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system ready; noise encapsulation available.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Slag Aggregate Production

Challenge: A major steel producer needed to process 250 TPH of blast furnace slag but faced weekly downtime due to wear part changes and conveyor damage from uncaptured metal.
Solution: Implementation of a turnkey slag crusher plant featuring a primary impactor with hydraulic adjustment, an overband magnet at the head pulley, and modular skid design.
Results: Wear part cycles extended from 6 weeks to 10 weeks. Metal removal exceeded 95%, eliminating related damage. The plant achieved an average availability of 95%, producing over 600,000 tons of certified construction aggregate annually.

Independent Slag Processing Contractor – Multiple Site Operations

Challenge: A contractor servicing multiple mills required a portable solution that could be relocated every 1824 months with minimal reinstallation cost and delay.
Solution: A semimobile slag crushing plant built on tripleaxle trailer modules with quickdisconnect electrical and hydraulic connections.
Results: Relocation time between sites reduced from one month to under two weeks. The consistent plant performance allowed standardized maintenance schedules across all client sites, improving operational predictability.

7. COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around throughput capacity and automation level:
Base Configuration (50150 TPH): Includes primary crushing stage, basic screening, manual adjustment systems.
Optimized Configuration (150300 TPH): Includes primary & secondary crushing stages automated metal separation PLC control system
HighCapacity Configuration (300+ TPH): Full circuit with tertiary crushing advanced dust suppression automated lubrication remote monitoring capability

Optional features include noise enclosures hot material handling packages specific wear protection alloys advanced particle shape optimization systems

Service packages are offered as annual maintenance contracts providing scheduled inspections guaranteed parts availability priority technical support Financing options include standard capital purchase finance lease agreements or tollprocessing partnerships where we operate the plant on your site

8. FAQ

1\. Is this plant suitable for processing stainless steel slag?
Our standard configuration is optimized for carbon steel BF/BOF slags For highly abrasive stainless steel slags we recommend specific metallurgy for wear parts which we provide as an option following material testing

2\. What are the expected operating costs per ton?
Based on historical data operating costs including power wear parts labor routine maintenance typically range between $0 $1 $2 per ton processed depending on local energy rates abrasiveness index of your specific slag

3\. How does this system integrate with our existing material handling equipment?
The plant is designed as a standalone node It includes feed hopper discharge conveyors can be interfaced with your existing belt systems via standardized chutework electrical connections We conduct pre installation interface reviews

4\. What training do you provide for our operations maintenance teams?
We provide comprehensive onsite training covering normal operation troubleshooting safety procedures routine maintenance tasks Documentation includes detailed operation manuals parts lists schematic diagrams

5\. What warranty period do you offer what does it cover?
We offer a standard months warranty on machinery workmanship defects extended warranties are available Critical components like crusher shafts main bearings carry specific warranty terms outlined in our commercial proposal