1. PAINPOINT DRIVEN OPENING

Managing slag is a critical but costly bottleneck in metal production and recycling operations. Inefficient processing directly impacts your bottom line through equipment wear, disposal expenses, and lost revenue from unrecovered metallics. Are you facing these persistent challenges?

High Abrasion Costs: Slag’s abrasive nature rapidly degrades standard crusher components, leading to frequent downtime for liner changes and rotor repairs, with replacement part costs cutting into operational budgets.
Metallic Recovery Inefficiency: Inadequate crushing leaves valuable ferrous and nonferrous metals locked within slag aggregates, resulting in significant lost revenue from unrecovered material.
Dust and Emission Control Failures: Processing generates fine particulate matter, creating compliance risks with environmental health and safety (EHS) standards and exposing personnel to hazardous dust.
Unreliable Throughput: Crushers not engineered for slag’s specific hardness and variability suffer from blockages, reduced capacity, and inconsistent output sizing, disrupting downstream material handling.
Regulatory Compliance Burden: Equipment that fails to meet stringent environmental directives, such as RoHS (Restriction of Hazardous Substances), can restrict the marketability of your processed slag byproducts.

The central question for plant managers is this: how can you achieve reliable, highvolume slag reduction while maximizing metal recovery, ensuring environmental compliance, and controlling total cost of ownership?

2. PRODUCT OVERVIEW

A RoHS compliant slag crusher plant is a purposeengineered stationary or semimobile system designed specifically for the primary and secondary crushing of metallurgical slag. It integrates robust size reduction technology with material handling and dust suppression systems to process slag into a calibrated aggregate while ensuring the final product adheres to RoHS substance restriction guidelines.

Operational Workflow:
1. Feed & PreScreening: Slag feedstock is loaded via excavator or conveyor into a hopper, often passing through a grizzly or scalping screen to remove oversize debris and direct fines away from the crusher.
2. Primary Size Reduction: The core crusher (typically a jaw crusher or impact crusher) receives the material, applying high mechanical force to break down large slag chunks.
3. Metal Separation & Recovery: Crushed material passes over an overhead magnetic separator (or eddy current separator for nonferrous metals) to extract liberated metallic fractions for recycling.
4. Secondary Crushing & Sizing (Optional): A secondary cone or impact crusher further reduces material to precise specifications, followed by screening decks to classify aggregate into defined fractions (e.g., 05mm, 520mm).
5. Dust Suppression & Control: Integrated water spray nozzles at transfer points and enclosed conveyor sections actively suppress dust emissions throughout the process.

Application Scope & Limitations:
Scope: Ideal for integrated steel plants, foundries, copper/nickel smelters, and metal recycling facilities processing blast furnace slag, steel slag, or nonferrous slags. Output is a commercially viable construction aggregate.
Limitations: Not designed for primary ore processing or extremely highmoisture materials without predrying. Plant throughput is fixed based on design; major capacity increases require system modification.

3. CORE FEATURES

HEAVYDUTY CRUSHING CHAMBER | Technical Basis: Highchrome iron or manganese steel liners with optimal nip angle geometry | Operational Benefit: Withstands extreme abrasion from sharpedged slag fragments, extending service intervals by up to 40% compared to standard chambers | ROI Impact: Reduces liner replacement costs and associated labor downtime directly impacting maintenance budgets.

INTEGRATED MAGNETIC RECOVERY SYSTEM | Technical Basis: Overbelt selfcleaning electromagnet or permanent magnet circuit positioned postcrushing | Operational Benefit: Automatically extracts liberated ferrous metal (often >95% recovery rate) from the crushed stream for direct resale or reuse | ROI Impact: Creates a secondary revenue stream; field data shows payback periods under 18 months based on recovered metal value alone.

CLOSEDLOOP DUST SUPPRESSION | Technical Basis: PLCcontrolled spray system with droplet size optimization for particulate agglomeration at key transfer points | Operational Benefit: Maintains airborne dust levels below 5 mg/m³ within the operating envelope, ensuring a safer workplace and regulatory compliance | ROI Impact: Mitigates risk of EHS fines and reduces longterm equipment wear caused by abrasive dust ingress.

ROHSCOMPLIANT COMPONENT AUDIT TRAIL | Technical Basis: Full material declaration documentation for electrical assemblies, hydraulics, wear parts (e.g., verifying absence of restricted substances like lead in solder) | Operational Benefit: Provides certified assurance that the processing plant does not contaminate slag aggregate with restricted substances | ROI Impact: Protects market access for your endproduct aggregates in regulated regions like the EU.

MODULAR PLANT DESIGN | Technical Basis: Bolttogether subassemblies for crushers, screens,and conveyors on a single heavyduty chassis | Operational Benefit: Enables faster site installation (~30% less time) and future reconfiguration or relocation as operational needs evolve | ROI Impact: Lowers initial civil works costs and preserves asset value through redeployability.

HIGHINERTIA ROTOR ASSEMBLY (For Impact Crusher Models) | Technical Basis: Densely packed rotor design with high mass moment of inertia| Operational Benefit: Maintains consistent rotational velocity under fluctuating feed conditions,cruising through hard spots without stalling,and producing a wellshaped cubicle end product| ROI Impact:Sustains target throughput rates reduces energy consumption per ton crushed,and improves product value for premium aggregate applications.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | RoHS Compliant Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Wear Life (Primary Chamber) | Standard Manganese Steel Liners | HighChrome Alloy Cast Liners with Reinforced Edges| +3540% Extended Life |
| Ferrous Metal Recovery Rate PostCrush| Manual picking or basic suspended magnet| Optimized OverBelt Magnetic Separator with Adjustable Height/Gap| +25% Recovery Efficiency |
| Average Dust Emission at Transfer Points| >10 mg/m³ without dedicated suppression| 50% Reduction |
| Plant Commissioning Time (Foundations Ready)| 46 Weeks for fixed foundation plants| 23 Weeks for modular skidmounted plants| ~40% Faster Deployment |
| Compliance Documentationfor EndProduct Aggregate| Supplier selfdeclaration only|certified RoHS component audit trail provided+ Material Safety Data Sheet support+ Regulatory defensibility |

5.TECHNICAL SPECIFICATIONS

Capacity / Throughput Rating: Modeldependent,ranging from 50 TPH to over 300 TPH of processed slag input.
Power Requirements: Primary drive typically requires 90 kW 250 kW electrical supply(400V/50Hz or as specified),with full plant auxiliary power demand up to350 kW.
Material Specifications: Crusher housing constructed from S355JR structural steel;liners available in AR400,Mn18%,or HiChrome27% iron;contact surfaces use stainless steel where requiredfor corrosion resistance
Physical Dimensions(Sample SkidMounted Plant): Approximate footprintof25m(L)x8m(W)x6m(H).Total weight varies between45120 tonnesbased on configuration
Environmental Operating Range: Designedfor ambient temperaturesfrom 20°Cto+45°C.Dust suppression system rated effective upto80% relative humidity.Electrical enclosures ratedtoIP65for protection against dustand water ingress

6 APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Management Challenge:Facing escalating landfill costsfor basic oxygen furnace(BOF)slagand pressureto improve metallic recovery ratesfrom existing inefficient crushing operations Solution Implementation:A300 TPH RoHS compliantslag crushing plantwith primary jaw crusher secondary impactor dualstage magnetic separationand threedeck final screen Results:Achieved consistent20mmminus aggregate product Metallic recovery increasedto96% generatingan additional revenue stream Landfill diversion reached85% within first yearof operation

Copper Smelter ByProduct Valorization Challenge Nonferrous smelter neededtoprocess granulated copperslaginto construction sandbut required strict controlover potential heavy metal contentin final productfor EU market access Solution Implementation A150 TPH specializedslag crusher plantfeaturing lined attrition scrubbersfor surface cleaning alongside precision crushing circuits Full RoHS compliance documentationprovidedforall plant components Results Produceda highquality fine aggregatesand meeting EN12620standards CertificationofRoHS compliance enabled premium pricingin European green construction projects

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are primarily determinedby throughput capacityand levelof automation Base systemsfor midrange capacity(~100TPH)startatthe investment leveltypicalfor heavy industrial processing machinery Optional featuresinclude advanced metal detectors(nonferrous), automated grease lubrication systems remote monitoring telematics packagesand additional screening modules Service packages typically offeredinclude scheduled preventive maintenance plans extended warranty coverageon wear partsand dedicated technical support Commercial financing optionssuchas equipment leasingor tailored rentaltoown programsare commonly availableto help manage capital expenditure

8 FAQ

Q1 How do I verifythe RoHS compliance claimformy processed aggregate
A The plant supplier providesa detailed component material declaration dossier This combinedwithyour own periodic chemical analysisofthe output aggregate servesas auditable proofthatthe processing equipment introducedno restricted substances

Q2 Can this plant handle wetor sticky slag materials
A While designedfordryor lowmoisture feed integrated vibratory prescreensand cascade feed systemscan manage moderate moisture For consistently highmoisture feedstock consultationis requiredas it may necessitate predrying steps

Q3 Whatisthe typical operational manpower requirement
A A welldesignedplantcan be operatedby one trained individualfrom a central control cabinwith supportfrom frontend loader operatorfor feeding Material samplingis conducted periodically but continuous manual interventionis not required

Q4 How does themetal recovery systemhandle varying sizesof liberated metal
A The primary overbelt magnet captures mediumtolarge ferrous pieces Secondary drum magnetsinstalledon discharge conveyors capture finer ferrous fractions For nonferrous recovery an optional eddy current separatorcan be integrated intothe flow sheet

Q5 Are spare parts subjecttothesame RoHS compliance standards
A Yes Genuine OEM spare partsare specifiedand manufacturedtomeetthe identical material restriction standardsasthe original equipment ensuring continuous compliance throughoutthe asset lifecycle

Q6 What infrastructureis requiredforsite installation
A Modular skidmounted plantsrequirea level compacted ground base adequate electrical supply connection pointsand accessfor water supplyforthe dust suppression system Detailed foundation drawingsare providedfor more permanent fixed installations

Q7 Is operator training providedwiththe purchase
A Comprehensive trainingforyour operationaland maintenance staffis standard covering safe operation routine maintenance procedures troubleshooting basic faultsand understandingthe control system