1. PAINPOINT DRIVEN OPENING

Managing slag byproduct is a persistent operational bottleneck with tangible costs. Are you facing these challenges?
High Disposal Costs & Liability: Landfilling slag is increasingly expensive and carries longterm environmental liability. Every ton processed onsite represents direct savings in haulage and tipping fees.
Inefficient Material Recovery: Valuable metallic content trapped in slag represents lost revenue. Inefficient liberation and separation mean you are leaving profit in the waste stream.
Equipment Wear & Unplanned Downtime: Abrasive slag rapidly degrades standard crusher components, leading to frequent maintenance shutdowns, high parts replacement costs, and unpredictable production halts.
Dust & Noise Compliance: Processing slag generates significant dust and noise, creating worker safety concerns and increasing the risk of noncompliance with stringent site environmental regulations.

What if your slag handling system could transform this liability into a recoverable asset while operating reliably within modern environmental and efficiency standards?

2. PRODUCT OVERVIEW

The ROHS Compliant Slag Crusher Plant is a turnkey processing system engineered for the size reduction, liberation, and recovery of metallic fractions from industrial slag. It is designed for stationary or semimobile installation at smelters, steel mills, and metal recycling facilities.

Operational Workflow:
1. Feed & PreScreening: Slag is fed via hopper and grizzly to remove fine fractions, directing only oversize material to the primary crusher.
2. Primary Size Reduction: A heavyduty crusher (typically jaw or impactor) breaks down large slag chunks to a manageable size.
3. Metal Liberation & Separation: Crushed material undergoes magnetic separation to extract ferrous metals. Further screening and crushing cycles ensure optimal liberation.
4. Final Sizing & Stockpiling: The processed aggregate is screened into specified grades (e.g., 010mm, 1040mm) for sale or reuse, while recovered metal is prepared for recycling.

Application Scope: Ideal for processing blast furnace (BF) slag, steel furnace slag, and nonferrous slags from copper or lead production.
Limitations: Not designed for primary rock mining or extremely highmoisture materials without predrying. Maximum feed size is determined by plant configuration.

3. CORE FEATURES

Advanced Crushing Chamber Design | Technical Basis: Computermodeled kinematics and wearpart geometry | Operational Benefit: Directs abrasive wear to replaceable liners, protects main machine body | ROI Impact: Extends major overhaul intervals by up to 40%, reducing lifetime capital outlay.

Integrated Magnetic Separation System | Technical Basis: HighGauss permanent overband and drum magnets | Operational Benefit: Continuous, automatic recovery of liberated ferrous metals directly from the crushing circuit | ROI Impact: Increases metal yield by 1525%, converting waste into direct revenue.

ROHSCompliant Dust Suppression | Technical Basis: Pressurized spray nozzles at transfer points with particle encapsulation technology | Operational Benefit: Suppresses airborne particulate at source, maintaining visible dust levels below 5 mg/m³ | ROI Impact: Eliminates costly dustrelated work stoppages and ensures continuous regulatory compliance.

Acoustic Damping & Enclosure System | Technical Basis: Composite sounddeadening panels on crusher and motors | Operational Benefit: Reduces operational sound pressure to below 85 dB(A) at 1 meter | ROI Impact: Protects worker hearing, minimizes noise complaints from surrounding communities, avoids mitigation fines.

HeavyDuty Component Specification | Technical Basis: Use of AR400/500 steel for liners, highgrade castings for rotors/frames | Operational Benefit: Withstands extreme abrasion from sharpedged slag aggregates | ROI Impact: Field data shows a 60% improvement in wearpart life compared to standard quarry crushers, lowering costperton crushed.

Centralized Greasing & Monitoring Points | Technical Basis: Manifolded lubrication lines to all critical bearings with diagnostic ports | Operational Benefit: Enables safe, rapid routine maintenance without disassembly | ROI Impact: Reduces scheduled lubrication downtime by 70% and prevents premature bearing failures.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Slag Plant | ROHS Compliant Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Metallic Recovery Rate (%)| ~85% (estimated) |>95% (measured) |>10% Improvement |
| Wear Part Lifetime (Hours) | ~8001200 hrs on liners |>2000 hrs on liners |>60% Improvement |
| Dust Emission Control| Basic bag filters or water sprays| Integrated multipoint suppression system |>80% Reduction in airborne particulates |
| Noise Emission Level| ~95105 dB(A)| 10 dB(A) Reduction |
| Mean Time Between Failure (MTBF)| ~450 hours |>750 hours |>65% Improvement |

5. TECHNICAL SPECIFICATIONS

Processing Capacity: Configurable from 50 TPH to 300 TPH.
Power Requirements: Primary crusher motor from 90 kW to 315 kW; total plant power dependent on configuration.
Feed Size Maximum: Up to 700mm lump slag.
Final Product Sizes: Adjustable via screen decks; typically producing 05mm sand substitute, 520mm aggregate.
Material Specifications: Primary frame construction from heavyduty steel plate; internal wear parts in AR400/500 steel; dust enclosure in galvanized sheeting.
Physical Dimensions (Typical Setup): Length ~25m x Width ~8m x Height ~6m (excluding feed hopper).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system rated effective up to 80% material moisture content.

6. APPLICATION SCENARIOS

Steel Mill – Blast Furnace Slag Processing

Challenge: A major steel producer faced rising landfill costs for granulated BF slag and needed to create a saleable construction aggregate while recovering residual iron.
Solution: Installation of a 200 TPH ROHS Compliant Slag Crusher Plant with twostage crushing and highintensity magnetic separation.
Results: Achieved >96% metal recovery. Produced over 450,000 tons annually of certified construction aggregate, eliminating disposal costs and generating new revenue streams. Payback period was under 24 months.

Copper Smelter – Waste Stream Valorization

Challenge: A smelter’s legacy slag piles contained locked copper units; traditional crushing methods were inefficient and created excessive dust emissions near site boundaries.
Solution: Deployment of a mobileconfiguration ROHS Compliant plant featuring enhanced dust control for onsite pile processing.
Results:Liberated an additional 34% copper content from old stockpiles for refining.Dust emissions remained within strict site limits throughout the project,demonstrating environmental compliance during remediation.

7. COMMERCIAL CONSIDERATIONS

Our ROHS Compliant Slag Crusher Plants are offered in three primary tiers:
1. Standard Configuration: Core crushing,magnetic separation,and basic dust control.For operations with existing infrastructure.Capital cost range:$350k $800k USD based on capacity.
2. Optimized Configuration (Most Common): Includes advanced acoustic enclosures automated grease systems,and enhanced multipoint dust suppression.Recommended for new installations.$500k $1M USD range
3. Fully Integrated Modular Plant: Includes feed conveyor prescreening module fines handling system,and centralized PLC control.Easily relocated.$750k $1M+ USD

Optional features include metal fragmentizers secondary eddycurrent separators for nonferrous metals remote monitoring telemetry

Service packages range from annual inspection plans to fullcostperton operating agreements ensuring predictable maintenance budgeting

Financing options include equipment leasing capital loansand payforperformance models tied to recovered metal tonnage

8.FAQ

Q:What defines 'ROHS Compliant' in this context?
A:The plant design specifically restricts the use of hazardous substances like lead mercury cadmium etc.in electrical components control systemsand paints ensuring the equipment itself meets international environmental directivesfor industrial machinery

Q Is this plant compatible with our existing conveyorand screening setup?
A Yes The plantis designed as modular skidmounted systemswith standardized discharge heightsand chute connectionsto interfacewith most existing material handling infrastructure Site surveysare conductedto confirm compatibility

Q How does the plant impact our operational manpower requirements?
A The centralized designand automated systems typically requirea crewof two operatorsfor monitoringand routine checks reducing labor intensity comparedto multiple standalone machines

Q What isthe expected timelinefrom orderto commissioning?
A For standard configurations deliveryis typically within16 weeks Commissioningand operator training requiresan additional2 weekson site dependingon foundationpreparation status

Q Are performance guarantees provided?
A Yes We provideguaranteesfor minimum throughput capacity maximum power consumptionand final product gradation basedon your specific feed material analysis