1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent, costly operational bottleneck. Are you facing these challenges?
High Downtime for Primary Crusher Maintenance: Frequent liner changes and unplanned breakdowns in your primary crushing circuit halt downstream processing, costing thousands per hour in lost production.
Excessive Wear Part Costs: The abrasive, often unpredictable nature of slag rapidly degrades standard crusher components, leading to unsustainable consumable expenses and frequent maintenance windows.
Inefficient Liberation of Valuable Metals: Incomplete crushing leaves encapsulated metals within slag aggregates, resulting in direct revenue loss from unrecovered materials and diminished product purity.
Inconsistent Feed Size & Throughput: Fluctuations in slag feed size and hardness cause chokefeeding or cavitation, preventing your plant from achieving stable, designed capacity.
High Operational & Safety Overheads: Manual breaking, frequent maintenance interventions, and dust generation increase labor costs and expose personnel to unnecessary risk.

Is your current solution equipped to handle the specific abrasiveness and density of slag while maximizing metal recovery and minimizing total cost of ownership?

2. PRODUCT OVERVIEW: LUXURY SLAG CRUSHER PLANT

The Luxury Slag Crusher Plant is a heavyduty, stationary or semimobile crushing system engineered specifically for the primary and secondary reduction of ferrous and nonferrous slags. It transforms large, irregular slag feed (up to 1.5m) into a precisely calibrated aggregate for further processing or sale.

Operational Workflow:
1. Primary Crushing: Dumpfed slag is reduced by a robust jaw crusher or gyratory crusher designed for extreme abrasion.
2. PreScreening & Metal Recovery: Initial screening separates fines; magnetic separation extracts liberated ferrous metals at the earliest stage.
3. Secondary Crushing & Shaping: A cone crusher or impact crusher with specialized liners performs tertiary reduction for optimal particle shape.
4. Final Screening & Classification: Multideck screens sort output into commercial aggregate fractions (e.g., 05mm, 520mm, 2040mm).
5. Dust Suppression & Control: Integrated spray systems maintain dust levels well below regulatory thresholds throughout the process.

Application Scope: Designed for integrated steel mills, copper smelters, metal recycling facilities, and standalone slag processing contractors handling blast furnace (BFS) or steelmaking slags (EAF/LD).

Limitations: Not suitable for primary crushing of virgin rock in hightonnage mining applications where slagspecific metallurgy is not required.

3. CORE FEATURES

HeavyDuty Rotor & Chamber Design | Technical Basis: High inertia kinematics with wearprotected impact plates | Operational Benefit: Sustains high throughput on dense (>2.8 t/m³) slag with minimal velocity loss | ROI Impact: Up to 15% higher consistent throughput versus standard designs reduces processing time per ton.

Liner Metallurgy Package | Technical Basis: Ceramicimbedded chromium carbide overlays on critical wear zones | Operational Benefit: Increases wear life by 34x in highly abrasive silicate matrix environments | ROI Impact: Reduces liner change frequency by over 60%, cutting parts inventory cost and maintenance labor.

Intelligent Tramp Metal Protection | Technical Basis: Hydraulic or pneumatic release system with autoreset functionality | Operational Benefit: Prevents catastrophic damage from uncrushable metals (e.g., tramp steel) without stopping the crusher | ROI Impact: Eliminates costly rotor repair/replacement events and associated production losses exceeding $50k per incident.

Adaptive Crushing Logic (ACL) | Technical Basis: PLCcontrolled variable drive adjusts closedside setting (CSS) based on realtime power draw | Operational Benefit: Maintains optimal product gradation despite variations in feed hardness and slab size | ROI Impact: Improves yield of highvalue aggregate fractions by an average of 12%, enhancing product revenue.

Integrated Dust Containment Skirting | Technical Basis: Multistage sealing at transfer points with negative pressure zones | Operational Benefit: Contains airborne particulate at source, maintaining plant cleanliness and operator safety | ROI Impact: Reduces housekeeping labor by an estimated 30% and ensures continuous compliance with environmental standards.

Modular Maintenance Platforms | Technical Basis: Engineered access platforms integrated into the plant superstructure | Operational Benefit: Provides safe, toolready access to all service points (liners, screens, belts) for faster maintenance | ROI Impact: Cuts scheduled maintenance downtime by up to 40%, increasing annual operating hours.

Centralized Greasing & Monitoring System| Technical Basis: Automated lubricant delivery to all major bearings with flow sensors| Operational Benefit: Ensures optimal bearing life under highload conditions and provides early failure warning| ROI Impact extends major bearing service intervals by ~25% prevents unplanned stoppages from lubrication failures

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Luxury Slag Crusher Plant Solution | Advantage (% Improvement) |
|||||
| Liner Wear Life (Abrasive Slag) | ~600 operating hours | ~2,200 operating hours | +267% |
| Metal Liberation Efficiency | ~8590% recovery postcrushing | ~9497% recovery postcrushing | +8% |
| Specific Power Consumption | ~0.9 1.1 kWh/ton | ~0.75 0.85 kWh/ton |18% |
| Mean Time Between Failure (MTBF) | ~450 hours |>720 hours |>+60% |
| Average Throughput Consistency ±15% from rated capacity ±5% from rated capacity |10pp variance |
| Dust Emission at Transfer Points >10 mg/m³ <5 mg/m³ |50%

5.TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 150 to 600 tonnes per hour.
Feed Size Maximum: Up to 1500 mm edge length.
Final Product Sizes: Adjustable from 05mm up to 040mm.
Primary Drive Power: From 160 kW to 400 kW depending on configuration.
Crusher Frame Construction: Welded steel plate with reinforced stress zones; minimum yield strength of 355 MPa.
Wear Part Specifications: Primary breaker plates manufactured from Xwin® or equivalent ceramic composite material.
Physical Footprint (Typical): Approximately Length=25m x Width=12m x Height=9m for a full circuit plant.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C with optional heating/cooling packages available.

6 APPLICATION SCENARIOS

Integrated Steel Mill – Blast Furnace Slag (BFS) Processing Challenge:

A major mill faced escalating landfill costs for BFS and needed to produce a highquality aggregate for cement substitution but struggled with rapid wear in their existing crushers causing unreliable supply contracts

Solution:

Implementation of a turnkey Luxury Slag Crusher Plant configured with primary jaw crusher ceramic liners ACL system

Results:

Achieved consistent production of SCMgrade aggregate Wear part costs reduced by $140k annually Secured a longterm offtake agreement based on reliable supply eliminating $80k/year in landfill fees

Copper Smelter – Recovering Residual Copper

Challenge:
A smelter’s legacy process failed to liberate fine copper trapped within granulated slag leading to an estimated $2M+ annual value loss in unrecovered metal alongside lowvalue aggregate

Solution:

Installation of a secondary/tertiary Luxury Slag Crusher Plant circuit featuring highreduction cone crushers precise screening enhanced magnetic separation

Results:

Copper recovery efficiency increased from %87 %96 Aggregate product value increased due cleaner mineral liberation Payback period on capital investment achieved in under months

7 COMMERCIAL CONSIDERATIONS

Pricing tiers are projectspecific based on required capacity modularity level
Base Plant Tier ( tph): Includes core crushing screening basic dust control
Premium Plant Tier ( tph): Adds ACL intelligent metal protection automated lubrication advanced dust suppression
Elite Turnkey Tier ( tph): Full plant design permitting modular erection commissioning training

Optional Features:
Hot Slag Handling Packages
Advanced Air Classification Systems
OnBoard Weighing Analytics
Remote Monitoring Diagnostics Portal

Service Packages:
Platinum Support:hour onsite response guaranteed parts availability annual health audits
Gold Support:hour remote support scheduled inspections parts discount
Bronze Support: Basic preventive maintenance schedule parts supply

Financing Options available include capital lease operating lease project financing terms tailored year cycles

8 FAQ

What if our slag composition varies significantly between batches?
The Adaptive Crushing Logic automatically compensates for hardness variations maintaining product consistency without manual intervention Field data shows gradation stability improves by over compared fixedsetting systems

How does this plant integrate with our existing material handling system?
Our engineering team conducts dimensional interface analysis All plants feature standardized discharge heights conveyor widths Electrical control systems are designed for integration into your existing PLC SCADA network

What is the expected operational availability?
Based on field performance data across installations designed operational availability exceeds when following prescribed maintenance protocols This factors in scheduled downtime liner changes

Are wear parts readily available?
Yes We maintain regional inventory critical wear components Furthermore our liner design utilizes longlife materials reducing change frequency Consumption rates are provided during feasibility stage accurate budgeting

Do you offer performance guarantees?
Yes We provide guaranteed minimum throughput maximum power consumption wear life rates key consumables These are contractually defined after review your specific slag analysis