1. PAINPOINT DRIVEN OPENING

Managing slag, a hard, abrasive byproduct, presents distinct operational and financial challenges. If your facility is considering a bulk order for slag processing equipment, you are likely confronting these critical issues:
High Downtime & Maintenance Costs: Conventional crushers not engineered for extreme abrasion suffer rapid wear on liners and blow bars, leading to frequent stoppages for component replacement and unplanned maintenance.
Inconsistent Throughput & Bottlenecks: Undersized or illsuited crushing stages create bottlenecks, preventing your plant from achieving target processing volumes and delaying material recovery cycles.
Poor Final Product Quality: Inefficient crushing can result in inconsistent grain size distribution, excessive fines, or unprocessed oversized material, reducing the market value of your recovered metal and aggregate.
High Operational Costs: The combined effect of high energy consumption per ton processed, frequent parts expenditure, and laborintensive maintenance directly erodes profit margins.

Are you evaluating how to reduce your costperton processed, increase system availability beyond 90%, and ensure a consistent, saleable product from your slag stream?

2. PRODUCT OVERVIEW: SLAG CRUSHER PLANT

A dedicated slag crusher plant is a stationary or semimobile system engineered specifically for the primary, secondary, and sometimes tertiary reduction of metallurgical slag. Its design prioritizes durability against abrasion and impact to transform large slag feed (often up to 800mm) into precisely graded aggregate (e.g., 020mm).

Operational Workflow:
1. Feed & PreScreening: Runoffurnace slag is fed via loader or conveyor. An optional prescalping screen removes fine fractions to bypass the primary crusher, increasing efficiency.
2. Primary Crushing: A heavyduty jaw crusher or impact breaker performs the initial size reduction, handling large chunks with high compressive strength.
3. Secondary & Tertiary Crushing: A cone crusher or further impact crusher stages refine the material to the desired intermediate size. This stage is critical for achieving cubical product shape.
4. Final Screening & Sorting: Vibrating screens classify the crushed material into precise commercial grades. Metal recovery systems (magnetic separators) are often integrated at this stage.

Application Scope & Limitations:
Scope: Ideal for integrated steel plants, copper/smelters, ferroalloy producers, and independent slag processing yards handling blast furnace (BF) slag, steel furnace slag, and nonferrous slags.
Limitations: Not designed for raw ore or natural rock mining where chemical composition differs significantly. Feed size must be controlled per plant design limits.

3. CORE FEATURES

HeavyDuty Rotor & Wear Assembly | Technical Basis: Highchromium martensitic steel castings with ceramic inserts | Operational Benefit: Withstands extreme abrasive wear from slag composites | ROI Impact: Field data shows a 4060% increase in wear life over standard manganese steel

MultiStage Crushing Circuit | Technical Basis: Optimized cavity designs across jaw/cone/impact stages | Operational Benefit: Delivers controlled size reduction with high yield of inspec product | ROI Impact: Reduces recirculating load by up to 30%, lowering energy cost per ton

Integrated Metal Recovery System | Technical Basis: Overband magnetic separators positioned at key transfer points | Operational Benefit: Automatically extracts ferrous metal for direct resale during processing | ROI Impact: Adds a direct revenue stream; improves final aggregate purity and value

PLCBased Automation & Monitoring | Technical Basis: Centralized control with load management and fault diagnostics | Operational Benefit: Enables singleoperator control; prevents overload damage; optimizes power draw | ROI Impact: Reduces labor requirements; minimizes unplanned downtime through predictive alerts

Modular Skid / Compact Foundation Design | Technical Basis: Preassembled modules with minimal interconnecting points | Operational Benefit: Significantly reduces civil work and installation time onsite | ROI Impact: Cuts installation costs by approximately 25% and accelerates commissioning

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Conventional Crusher) | Our Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Wear Part Lifetime (Primary) | ~40,000 MT throughput before major changeout| ~65,000 MT throughput before major changeout| +62% |
| System Availability (Scheduled) | 8085% (factoring maintenance stops) |> 92% (optimized service access) |> +12% uptime |
| Power Consumption per Ton Processed| Baseline of X kWh/tonne| Reduced by optimized drive & load management| 15% to 20% |
| Product Yield (InSpec Aggregate)| ~8588% of total feed| >93% of total feed through precise staging| +58% yield gain |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to over 300 TPH for bulk order requirements.
Feed Size Maximum: Up to 800mm edge length (dependent on model).
Final Product Size Range: Adjustable between 05mm up to 040mm.
Power Requirements: Plantwide requirement from 150 kW up to 600 kW; designed for standard industrial voltage supply (400V/6kV/11kV).
Key Material Specifications: Primary wear parts manufactured from Nihard or highchrome alloys; structural frames use heavyduty S355JR steel.
Physical Dimensions (Typical Skid): Varies by capacity; e.g., Primary module approx. L12m x W4m x H5m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; dustsuppressed enclosures standard.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Modernization

Challenge: A major steel producer faced escalating disposal costs and needed to process legacy slag dumps while handling daily furnace output. Their existing singlestage crusher had low recovery rates and high downtime.
Solution Implementation of a turnkey twostage slag crusher plant with primary jaw crusher and secondary cone crusher circuit including magnetic separation at two stages.
Results Achieved a processing rate of 180 TPH with metal recovery exceeding 96%. The consistent aggregate produced was sold to the local construction sector creating new revenue offsetting operating costs entirely.

Independent Slag Processing Contractor

Challenge A contractor securing multiyear slag supply contracts required a reliable plant that could be deployed across different sites with minimal setup time while guaranteeing product specifications for various buyers.
Solution Supplied a semimobile skidmounted slag crushing plant with all electrics onboard requiring only power hookup and feed conveyor connection.
Results The contractor reduced site commissioning time from weeks to days enabling faster project startup The plants consistent output met stringent rail ballast specifications securing a premiumpriced offtake agreement

7 COMMERCIAL CONSIDERATIONS FOR BULK ORDERS

Pricing tiers are structured around capacity throughput core configuration complexity:
Tier I Base Plant Standard duty components capacities up to TPH ideal for consistent lowerabrasion slags Tier II HeavyDuty Plant Enhanced wear protection highercapacity drives capacities TPH designed for highly abrasive mixed slags Tier III Custom Engineered Systems Multistage circuits full automation integration specific screeningmetal recovery layouts Optional Features Include dust suppression systems advanced metal detectors nonferrous separation modules remote monitoring telemetry Service Packages Available as annual comprehensive coverage plans covering scheduled maintenance wear part kits priority support Financing Options For qualified buyers we offer leasing structures operating leases or project financing solutions in partnership with industrial lenders

8 FAQ

What types of metallurgical slags can this plant process?
The plants are engineered primarily for ferrous slags blast furnace BOF EAF Common nonferrous slags copper nickel can also be processed though liner material selection may be adjusted based on specific abrasiveness analysis

How does this system integrate with our existing material handling equipment?
Plants are designed as complete circuits but can be interfaced via standardized conveyor dimensions transfer heights Our engineering team reviews your existing layout feeddischarge points during quotation

What is the expected operational cost per ton processed?
While sitespecific factors apply industry data from similar installations indicates operational costs including power maintenance parts labor typically range between $X$Y per metric ton excluding feedstock cost

What commercial terms are available for bulk orders?
For orders involving multiple units we offer structured discounts extended warranty terms prioritized production scheduling Dedicated project management is assigned

What is the typical implementation timeline after order placement?
For standard skidmounted designs delivery is within weeks following factory acceptance testing Site installation commissioning typically requires weeks depending on foundation readiness