1. PAINPOINT DRIVEN OPENING

Managing bulk slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
High Disposal Costs & Lost Revenue: Landfilling slag represents a direct financial loss and increasing disposal fees. Valuable metallic content is wasted, and potential revenue from processed aggregate is unrealized.
Inefficient Primary Size Reduction: Oversized, irregular slag chunks from ladles or pits cause frequent bridging in feeders, leading to unplanned downtime for manual clearing and damaging downstream equipment.
Excessive Wear & Maintenance Costs: The abrasive nature of slag rapidly degrades standard crusher components, resulting in high parts replacement costs, labor for changes, and production stoppages.
Inconsistent Final Product: Without controlled crushing, output size varies widely. This leads to poor performance in secondary processing or makes the aggregate unsuitable for consistent sale as a construction material.
Space & Throughput Limitations: Stationary crushing circuits may be geographically fixed and costly, while inadequate mobile solutions lack the throughput and durability for continuous bulk slag processing.

The central question for plant managers is this: how can you transform a costly waste stream into a controlled, profitable product line while achieving reliable, hightonnage throughput?

2. PRODUCT OVERVIEW

The solution is a purposeengineered Bulk Slag Crusher Plant. This is a heavyduty, semimobile or skidmounted primary crushing system designed specifically for the initial reduction of large, abrasive metallurgical slag.

Operational Workflow:
1. Feed & PreScreening: Bulk slag is loaded via excavator or loader into a robust vibrating grizzly feeder, which bypasses subsize material and evenly feeds oversized chunks to the crusher.
2. Primary Crushing: A highinertia jaw crusher or impactor applies massive force to break down large slabs (often up to 1.5m) into manageable fragments (typically 200mm to 250mm).
3. Discharge & Conveying: Crushed material is discharged onto a heavyduty belt conveyor system for transport to the next stage—stockpiling, secondary crushing, or magnetic separation.

Application Scope: Ideal for steel mills, foundries, and metal recycling yards processing blast furnace (BF) slag, basic oxygen furnace (BOF) slag, electric arc furnace (EAF) slag, and ladle slag.
Key Limitation: This plant is designed for primary reduction. For specific graded aggregates (e.g., 20mm), a secondary crushing and screening circuit will be required downstream.

3. CORE FEATURES

HeavyDuty Vibrating Grizzly Feeder | Technical Basis: Highstress amplitude drive system | Operational Benefit: Eliminates bridging of sticky or oversized slab slag; protects crusher from direct loader impact | ROI Impact: Reduces feederrelated downtime by an estimated 6080% versus standard apron feeders

AbrasionResistant Crusher Design | Technical Basis: Manganese steel jaws/liners with optimized nip angle; reinforced rotor assemblies | Operational Benefit: Extends wear life in highly abrasive slag environment; maintains consistent gap setting | ROI Impact: Lowers costperton for wear parts by 3050% compared to standard quarry crushers

Integrated Metal Trap & Bypass | Technical Basis: Permanent overbelt magnet or pneumatic tramp metal release system | Operational Benefit: Removes uncrushable metallic “tramp” (e.g., bucket teeth, rebar) before it enters the crushing chamber | ROI Impact: Prevents catastrophic damage; eliminates associated repair costs and extended downtime

PLCBased Control & Monitoring System | Technical Basis: Centralized control panel with amp draw monitoring, bearing temperature sensors | Operational Benefit: Allows operators to optimize feed rate; provides early warning for mechanical issues | ROI Impact: Enables predictive maintenance scheduling; improves overall plant availability by optimizing crusher load

Modular SkidMounted Design | Technical Basis: Preassembled structural steel skid with integrated walkways and maintenance platforms | Operational Benefit: Significantly reduces onsite installation time and civil works cost; facilitates relocation within site | ROI Impact: Faster commissioning (weeks vs. months); improves capital flexibility

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Generic Mobile Plant) | Bulk Slag Crusher Plant Solution | Advantage (% improvement) |
| : | : | : | : |
| Wear Part Life in Slag Duty | 3045 days for jaw liners | 75100 days for specialized liners | +110% to +120% |
| Availability (Uptime) | ~80%, frequent stops for clearing/breakdowns| ~92%, designed for continuous duty| +15% operational time |
| Throughput Consistency| Fluctuates with feed bridging/abrasion| Stable output due to feeder design & power reserve| +25% more predictable tons/hr |
| Tramp Metal Damage Events| Several per year requiring major repair| Nearzero with integrated protection systems| ~100% reduction in related incidents |

5. TECHNICAL SPECIFICATIONS

Capacity / Rating: 400 – 1,200 tonnes per hour (TPH), depending on feed size and required product.
Power Requirements: Total installed power typically 300 – 600 kW. Configured for 400V/50Hz or 480V/60Hz industrial supply.
Material Specifications: Fabricated from S355JR structural steel; wear surfaces use HARDOX® or equivalent; crusher liners in premium manganese steel (1822% Mn).
Feed Opening / Capacity: Primary crusher accepts feed sizes up to 1500mm x 1200mm.
Physical Dimensions (Typical): Skid length: 18m; Width: 4m; Height (to top of feeder): 6m. Approximate weight: 90 – 160 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression spray systems are standard.

6. APPLICATION SCENARIOS

Integrated Steel Mill – Blast Furnace Slag Processing

Challenge: A mill faced escalating landfill costs for BF slag and needed to recover metallics while producing a saleable aggregate. Their existing system suffered from low throughput and constant jamming.
Solution: Implementation of a highcapacity Bulk Slag Crusher Plant with an overbelt magnet installed after the primary crusher.
Results: Landfill volume reduced by over 85%. Recovered metallics returned to the furnace process stream produced significant annual savings. The consistent 250mm crushed aggregate became a new revenue source.

Electric Arc Furnace MiniMill

Challenge: Processing EAF slag was causing extreme wear on a generalpurpose jaw crusher, requiring liner changes every month at high cost and production loss.
Solution: Installation of a dedicated Bulk Slag Crusher Plant engineered with abrasionresistant alloys and optimized geometry specifically for EAF slag characteristics.
Results: Wear part life extended to over three months per set. Maintenance labor hours dedicated to the primary crushing stage were reduced by approximately 65%, directly lowering operating costs.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers:
Base Configuration (Skidmounted Jaw Crusher Plant): For operations prioritizing robustness over ultimate fines production.
Enhanced Configuration (Skidmounted Impact Crusher Plant): For applications where a slightly higher proportion of fines in the primary product is acceptable or desired.
Full Circuit Configuration (Primary + Secondary Modules): For turnkey production of specific aggregate sizes directly at the source.

Optional Features / Upgrades: Hydraulic adjustment systems for CSS changeovers, advanced dust suppression/filtration modules,
hotslag handling kits,
extended conveyor systems,
and dualpower capability (diesel/electric).

Service Packages: Available tiers include Basic Warranty,
Extended Wear Part Guarantees,
Annual Inspection Contracts,
and Comprehensive OnSite Maintenance Agreements with guaranteed response times.

Financing Options: Equipment can be acquired via direct purchase,
operational lease structures tailored to project cash flow,
or through longterm rentaltoown agreements.

8.FAQ

1.Q:What are my foundation requirements?
A:The skidmounted design distributes load but requires a level compacted base—typically packed gravel or lean concrete—minimizing extensive civil works compared to stationary plants.

2.Q:What about dust control?
A.The plant includes standard spray nozzle systems at transfer points.For indoor installations or strict environmental regulations,a baghouse filtration module can be added as an option.

3.Q:What ongoing maintenance should we expect?
A.Daily greasing checks,vibrating equipment inspections,and regular monitoring of wear liners.Field data shows planned liner changes are the primary maintenance activity,scheduled based on processed tonnage rather than time.

4.Q:What happens if uncrushable material enters?
A.The integrated tramp metal protection system(overbelt magnet or release system)is designed as the first defense.For extreme events,the hydraulic toggle adjustment on jaw models(or impactor curtain systems)allows relief without causing catastrophic failure.

5.Q:What lead time can we expect from order?
A.For standard configurations,the lead time typically ranges between16to24weeks.This includes engineering,fabrication,factory assembly,and testing prior to shipment