1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Your operation likely faces these challenges: unprocessed slag piles consuming valuable yard space and representing lost revenue from recoverable metals; inconsistent feed size causing downstream processing inefficiencies and increased wear on conveyors and separators; excessive dust generation during crushing leading to environmental noncompliance, health risks, and site cleanup costs; premature equipment failure due to the highly abrasive nature of slag, resulting in unscheduled downtime and high parts replacement frequency; and the logistical expense of transporting uncrushed material offsite for processing.

Are these issues impacting your bottom line? How much production time is lost to maintenance? What is the true cost of noncompliance and inefficient metal recovery? A purposeengineered ROHS Compliant Slag Crusher Plant is the systematic answer.

2. PRODUCT OVERVIEW

This is a stationary or semimobile crushing circuit specifically engineered for ferrous and nonferrous slag reduction. It transforms large, irregular slag feed from furnaces or stockpiles into a precisely graded aggregate for sale or a controlledsize feedstock for metal recovery processes.

Operational Workflow:
1. Primary Size Reduction: Large slag chunks (up to 800mm) are fed into a robust primary jaw crusher for initial breakage.
2. Metal Separation & Scalping: Crushed material passes over an overhead magnetic separator to remove liberated ferrous metals, followed by a vibrating grizzly to scalp out fines.
3. Secondary/Tertiary Crushing: Oversize material is conveyed to a secondary cone or impact crusher for further reduction to the target product size (typically 040mm).
4. Final Sizing & Stockpiling: The crushed product is screened via a multideck screen, with oversize recirculated and correctly sized material conveyed to stockpiles.

Application Scope: Ideal for integrated steel plants, copper/nickel smelters, foundries, and standalone slag processing yards handling blast furnace (BFS) or steel furnace slag.
Limitations: Not designed for primary rock mining or extremely highmoisture claybased materials without preprocessing.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: Reinforced manganese steel jaws & oversized bearings | Operational Benefit: Sustained throughput of highly abrasive slag with minimal deformation or seizure risk | ROI Impact: Reduces primary crusher replacement cycle by up to 40%, lowering costpertonne

Integrated Magnetic Separation | Technical Basis: Overbelt selfcleaning electromagnet positioned postprimary crush | Operational Benefit: Earlystage removal of liberated ferrous metals protects downstream conveyors and crushers from tramp metal damage | ROI Impact: Recovers valuable metal scrap directly and can reduce downstream maintenance costs by an estimated 1525%

ROHSCompliant Dust Suppression System | Technical Basis: Encapsulated transfer points with strategically placed fine mist spray nozzles using minimal water | Operational Benefit: Actively suppresses airborne particulate at source, maintaining workplace air quality standards | ROI Impact: Mitigates risk of regulatory fines and reduces housekeeping labor by an average of 8 hours per week

Centralized Greasing & Condition Monitoring | Technical Basis: Automated lubricant delivery to key bearing points with visual inspection ports | Operational Benefit: Ensures critical components operate within specified parameters, extending service life | ROI Impact: Enables predictive maintenance, preventing catastrophic bearing failures that can cause 2472 hours of unplanned downtime

Modular, BoltTogether Design | Technical Basis: Prefabricated structural modules with flanged connections | Operational Benefit: Significantly reduces civil works and onsite assembly time compared to welded designs | ROI Impact: Cuts installation costs by approximately 30% and allows for future plant reconfiguration or relocation

HighAngle/LowSpeed Feed Conveyor | Technical Basis: Chevronpatterned belt with deep cleats operating at optimized speed | Operational Benefit: Prevents rollback of slabby slag material during inclined transport, ensuring consistent feed to the crusher hopper | ROI Impact: Eliminates feedrelated stoppages, maximizing plant uptime and throughput consistency

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | ROHS Compliant Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Tonnage Processed per Maintenance Hour| 8001,000 tonnes/hour between scheduled stops| 1,2001,500 tonnes/hour between scheduled stops| +50% operational availability |
| Metal Recovery Efficiency (Ferrous)| ~8590% recovery rate| 9497% recovery rate via optimized magnet placement| +7% increase in reclaimed metal value |
| Dust Emissions at Transfer Points| >50 mg/m³ (requiring additional control)| Consistently 60% reduction in particulate output |
| Power Consumption per Tonne| Varies widely; often not optimized| Engineered drive systems & efficient crusher chambers reduce draw| Field data shows 812% lower kWh/tonne |
| Installation & Commissioning Timeline| 46 weeks for fixed foundation plants| 23 weeks for modular bolttogether plants| ~50% faster timetooperation |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to over 300 TPH.
Feed Size: Maximum lump size up to 800mm x 1200mm.
Power Requirements: Total connected load typically between 150 kW 450 kW depending on configuration (380V/415V /50Hz/60Hz).
Material Specifications: Crusher liners in premium manganese steel (18%22%); structural frames in heavyduty S355JR steel; wear liners at chutes in AR400 steel.
Physical Dimensions (Typical Setup): Footprint approximately 25m (L) x 15m (W) x 12m (H). Modular design allows adaptation.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression system effective up to 80% relative humidity.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Management

Challenge: A major steel producer faced growing BOF slag stockpiles with inconsistent metal recovery. Manual sorting was inefficient, and their existing crusher suffered frequent liner failures.
Solution: Implementation of a turnkey ROHS Compliant Slag Crusher Plant with primary jaw crusher, secondary cone crusher, and twostage magnetic separation.
Results: Achieved a consistent 25mm product for road base sales. Metal recovery efficiency increased from ~82% to 96%, adding significant revenue. Planned liner changes replaced unpredictable breakdowns.

Copper Smelter Tailings Reprocessing

Challenge: Historical slag dumps contained locked copper particles but were too heterogeneous for costeffective processing with mobile equipment.
Solution: A semimobile ROHS compliant plant was installed onsite with highwear resistant impact crushers tailored for abrasive nonferrous slag.
Results: The plant processes 200 TPH of legacy material. The controlled crushing size liberation improved downstream flotation recovery by 18%, turning a liability into a profitable operation.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers:
Base Configuration: Includes primary crushing, basic conveyor system, and electrical control panel.
Enhanced Configuration: Adds secondary crushing stage, magnetic separator(s), dust suppression kit, and advanced PLC automation.
Turnkey Solution: Full engineering design, civil works support, installation supervision, commissioning, and operator training package.

Optional Features: Metal detector prior to primary crusher; hot slag handling modifications; sound attenuation enclosures; automated sampler systems; remote monitoring telematics.

Service Packages:
Annual Maintenance Contract: Scheduled inspections, lubrication kits,
10% discount on spare parts.Performance Care Package: Includes above plus quarterly vibration analysis,
guaranteed emergency response time,
fixedcost annual parts bundle.Financing Options: Equipment leasing structures,
renttoown agreements,
or project financing available through accredited partners typically over
36
60 month terms.

8.FAQ

Q:What defines 'ROHS Compliant' in this context?
A:The plant design prioritizes environmental protection through integrated engineering controls.The dust suppression system ensures airborne particulate meets strict workplace exposure limits,and the electrical system components are specified without restricted hazardous substances per the EU directive.It signifies a plant built for modern regulatory compliance.

Q Can this plant process wet or clumpy slag?
A While designed for typical aircooled slag,surface moisture is managed by the dust suppression system.Highly saturated or claycontaminated material may require prescreening or blending with drier feed.Consult our engineering team for specific material testing recommendations.

Q How does this solution improve our overall metal recovery profitability?
A By positioning highintensity magnetic separation immediately after primary crushing,the system recovers clean liberated metal early.This prevents it from being repeatedly processed reducing degradation into fines which are harder to recover.The result is higher yield of premiumgrade scrap alongside protected downstream equipment.

Q What is the expected lifespan of key wear parts?
A Under normal operating conditions industry testing demonstrates primary jaw liners last
1200
1500 operating hours secondary concave/mantle sets last
1800
2200 hours.Wear life varies based on specific slag abrasiveness index(S.A.I)and throughput which we factor into our performance projections.

Q Are your plants compatible with our existing conveyor infrastructure?
A Yes.Engineering specifications include detailed interface points(feed height discharge height belt width capacity).We design transfer chutes and supports to integrate seamlessly with your current layout minimizing retrofit costs during procurement planning we require your site layout drawings

Q What training do you provide for our operations team?
A We provide comprehensive training covering safe startup/shutdown procedures routine maintenance checks troubleshooting common issues,and basic control system operation.Training occurs during commissioning using your actual plant Documentation includes full operational manuals parts lists schematic diagrams