1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent operational bottleneck with tangible costs. Are you facing these challenges?
High Disposal Costs & Liability: Landfill fees for untreated slag are escalating, and improper storage creates environmental liability.
Inefficient Material Handling: Oversized, irregular slag chunks cause feeder blockages, conveyor damage, and significant downtime for manual breaking or equipment clearing.
Lost Revenue Streams: Valuable metallic content remains trapped within the slag, and inconsistent particle size limits profitable resale as aggregate or industrial feedstock.
Premature Equipment Wear: Abrasive slag accelerates wear on downstream processing equipment, leading to frequent part replacement and unplanned maintenance stops.
Space Constraints & Safety Hazards: Accumulating stockpiles consume valuable plant space, while unstable piles and dust generation pose safety risks.

The core question is: how do you transform this problematic byproduct from a cost center into a controlled, revenuegenerating process? The answer lies in a purposeengineered China slag crusher plant.

2. PRODUCT OVERVIEW

A China slag crusher plant is a stationary or semimobile crushing circuit specifically configured for the size reduction and liberation of materials like blast furnace slag, steel slag, and nonferrous smelter slag. It is engineered to handle hightemperature tolerance, high abrasiveness, and occasional tramp metal.

Operational Workflow:
1. Primary Crushing/Jaw Crushing: Large slag feed (up to 1m+) is reduced to a manageable size (approx. 150250mm) using a robust jaw crusher or hydraulic impact hammer.
2. Magnetic Separation (Critical Stage): A suspended selfcleaning magnet or magnetic drum over a conveyor removes liberated ferrous metals for recovery and sale.
3. Secondary/Tertiary Crushing: Cone crushers or impact crushers further reduce the material to the target product size (e.g., 040mm), ensuring complete liberation of remaining metallics.
4. Screening & Sorting: Vibrating screens classify the crushed material into specified fractions for different market applications (e.g., road base, cement additive).
5. Final Metal Recovery: A secondstage magnetic separator captures any remaining fine ferrous content.

Application Scope & Limitations:
Scope: Ideal for integrated steel mills, foundries, metal smelting plants, and dedicated slag processing yards. Effective on aircooled blast furnace (BF) slag and basic oxygen furnace (BOF) steel slag.
Limitations: Not suitable for processing molten slag without specialized cooling systems. Feed material with excessive claylike consistency or very high moisture may require preprocessing to prevent clogging.

3. CORE FEATURES

HeavyDuty Jaw Crusher | Technical Basis: High manganese steel jaws & reinforced frame design | Operational Benefit: Sustained throughput of large, hard slab slag with minimal deformation; handles occasional uncrushables via hydraulic toggle adjustment | ROI Impact: Reduced primary stage downtime by up to 30% versus standard crushers in abrasive service

Integrated Magnetic Separation System | Technical Basis: Multistage arrangement of permanent and electro magnets across main conveyors | Operational Benefit: Continuous, automated recovery of ferrous scrap directly within the crushing circuit without separate handling | ROI Impact: Direct revenue generation from recovered metal; protects downstream crushers from damage

AbrasionResistant Liner System | Technical Basis: Replaceable liners made from AR400/500 steel or ceramic composites in highwear zones | Operational Benefit: Extends service intervals for hoppers, chutes, and crusher cavities exposed to constant abrasive flow | ROI Impact: Lowers costperton for wear parts by an average of 25% and reduces maintenance labor hours

Centralized Greasing & Hydraulic System | Technical Basis: Automated lubrication points for bearings and centralized hydraulic power unit for adjustments | Operational Benefit: Ensures critical components are lubricated under all conditions; allows safe remote adjustment of crusher settings for product size changes | ROI Impact: Increases bearing service life by up to 40%, preventing costly failures

Vibration Damping Foundations | Technical Basis: Engineered base frame with antivibration pads or custom concrete foundation plans provided | Operational Benefit: Minimizes transmitted vibration to surrounding structures; ensures stable operation of sensitive screening equipment | ROI Impact: Reduces longterm structural maintenance costs and improves screening accuracy for better product quality

PLCBased Control & Monitoring Panel | Technical Basis: Programmable Logic Controller with touchscreen HMI displaying amperage, temperature, and production metrics | Operational Benefit: Operators can monitor plant health from a central location; automated sequences prevent incorrect startup order which can cause blockages | ROI Impact: Enables oneperson operation; diagnostic data reduces meantimetorepair by an estimated 20%

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | This Slag Crusher Plant Solution | Advantage (% improvement) |
|||||
| Metallic Recovery Rate | ~8590% | >96% | +611% increased yield |
| Wear Part Life (Primary) | 80,000 120,000 tons | 150,000 200,000 tons | +60% extended service |
| Specific Power Consumption | Varies widely Optimized motorcrusher matching & efficient drive design Up to 15% lower kWh/ton |
| Average Availability ~85% >92% +7% more uptime |
| Dust Emission Control Basic bag filters Multistage cyclone + bag filter system Exceeds local environmental standards |

5. TECHNICAL SPECIFICATIONS

Processing Capacity: Configurable from 50 TPH to over 400 TPH.
Feed Size Maximum: Up to 1000mm x 1200mm slab material.
Final Product Size Range: Adjustable between 05mm to 040mm.
Power Requirements: Total installed power from 200kW to 800kW+ depending on configuration; standard supply at 380V/50Hz/3Phase (other voltages available).
Key Material Specifications:
Main Frame & Hopper: Q345B Carbon Steel
HighWear Liners & Jaw Plates：Mn18Cr2 / AR450 Steel
Conveyor Belting：EP400/3 with high abrasionresistant covers
Physical Dimensions (Typical Setup): Length ~4070m x Width ~1525m x Height ~1218m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust emission concentration <20mg/Nm³.

6. APPLICATION SCENARIOS

Integrated Steel Mill Slag Yard Challenge:

Specific Problem:
A major mill faced rising landfill costs for steel slag stockpiles exceeding ten years. The hardened slabs contained recoverable metal but were too dense for older equipment.

Solution:
Implementation of a turnkey China slag crusher plant featuring a primary hydraulic jaw crusher for slab breaking and two stages of magnetic separation.

Results:
Quantifiable Outcomes:
The plant processes over 250 TPH of legacy stockpile material. Ferrous metal recovery generates over $1.2M USD annually in additional revenue. The consistent aggregate produced is sold to local road construction projects.

Copper Smelter Slag Processing Challenge:

Specific Problem:
A smelter needed to liberate entrapped copper granules from granulated slag before disposal. Existing hammer mills created excessive fines (10mm) that were difficult to separate via gravity methods.

Solution:
Installation of a specialized China slag crusher plant using a multicavity impact crusher configured for controlled shattering rather than pulverizing.

Results:
Quantifiable Outcomes:
Liberation efficiency improved by over X%. The resulting coarse granule concentrate achieved higher purity (>90%), significantly improving smelter return rates while reducing tailings volume by X%.

7. COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around capacity and automation level:

1. Standard Tier (100150 TPH): Includes core crushing circuit with basic magnetic separation and manual controls.
2.Performance Tier (200300 TPH): Adds secondary crushing stage，PLC automation，enhanced dust suppression，and comprehensive wear monitoring sensors.
3.Premium Tier (300+ TPH): Fully automated system with remote monitoring capability，advanced metal detection，and spare parts package.

Optional Features：
• Mobile primary crushing module on tracks
• Additional nonferrous metal sorting（eddy current separator）
• Complete soundproofing enclosures
• Preengineered steel structure building

Service Packages：
• Commissioning & Operator Training（Standard）
• Annual Preventive Maintenance Contract（Recommended）
• Full Wear Parts Supply Agreement（for predictable costperton）

Financing Options：
Direct purchase，leasing arrangements，and project financing solutions are available through partnered institutions，often tailored based on projected ROI from metal recovery.

8.FAQ

Q：Can your China slag crusher plant integrate with our existing conveyors和screening system？
A：Yes。Engineering drawings can be provided early in the process。Our plants are designed as modular systems。Inlet和outlet points，as well as control signals，can be interfaced with your current infrastructure。

Q：What is the expected operational impact on our maintenance team？
A：Your team will require training on new PLC controls和specialized wear part更换 procedures。The centralized lubrication和modular liner design aim to simplify routine tasks。Field data shows maintenance hours per ton processed typically decrease after the initial learning period。

Q：How do you ensure consistent quality across different production batches？
A：We employ standardized design platforms和source key components（bearings，motors，crusher castings）from certified Tier1 suppliers。Every plant undergoes fullload factory acceptance testing（FAT）with customerwitnessed performance verification before shipment。

Q：What commercial terms are standard？
A：Standard terms are FOB Chinese port或CIF destination port。Payment commonly involves an advance payment against proforma invoice，a payment against shipping documents，and retention upon successful commissioning。

Q：What does implementation typically involve on our site？
A：It requires prepared foundations（plans supplied），adequate utility connections（power，water），and crane access。Our scope includes supervision of mechanical erection，electrical connection指导,and commissioning。Total onsite time varies from X到Y weeks depending on scale。

Q：How is tramp metal（e.g., bucket teeth）handled？
A：The primary jaw crushers in our configuration include hydraulic overload protection that allows uncrushable objects to pass without catastrophic failure。These are then removed manually at the first magnetic separation point。

Q：What kind of output particle shape can be expected？
A：Using our recommended secondary cone crusher configuration produces more cubical product ideal for aggregate markets。An impact crusher secondary stage yields a slightly more fractured shape suitable as railway ballast。This choice depends on your target product specification