1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
High Downtime & Maintenance Costs: Frequent clogging and abrasive wear in standard crushers lead to unscheduled stops, excessive part replacement, and lost processing hours.
Inefficient Material Liberation: Inconsistent crushing fails to fully separate metal from slag, resulting in valuable ferrous recovery left in the waste stream and lost revenue.
Throughput Limitations: An undersized or improperly configured slag crusher plant creates a backlog, stalling upstream steelmaking operations and downstream material handling.
High Operational Costs: Excessive power consumption from inefficient crushing mechanisms and the laborintensive management of multiple, disparate units erode profit margins.
Dust & Noise Compliance: Uncontrolled particulate emissions and noise levels from crushing operations risk regulatory noncompliance and create unsafe workplace conditions.

The question for plant managers is clear: how can you transform slag from a costly byproduct into a streamlined, profitable recovery operation while ensuring reliability and compliance?

2. PRODUCT OVERVIEW

A modern Slag Crusher Plant is a purposebuilt, integrated processing system designed for the efficient reduction and liberation of slag from steel mills, smelters, and foundries. Its core function is to crush large slag lumps into finely graded aggregate, maximizing the recovery of entrapped metallic content.

Operational Workflow:
1. Primary Crushing: Large slag feed (up to 1000mm) is reduced by a heavyduty jaw crusher or impactor capable of handling highabrasion material.
2. Magnetic Separation: Initial recovery of liberated metallic pieces via suspended or drum magnets integrated into the conveyor system.
3. Secondary & Tertiary Crushing: Further size reduction via cone crushers or impactors to ensure complete metalslag liberation.
4. Screening & Final Separation: Material is classified by vibratory screens; oversize is recirculated, while correctly sized aggregate passes under additional magnetic separators for final metal extraction.
5. Stockpiling/Transport: Cleaned slag aggregate is conveyed to stockpiles for sale or reuse; recovered metal is collected for recycling.

Application Scope: Ideal for integrated steel plants, minimills, copper smelters, and ferrous/nonferrous foundries. Designed for blast furnace (BF) slag, steel furnace slag, and similar metallurgical byproducts.

Limitations: Not designed for primary ore processing or extremely hard, nonmetallic minerals. Feed size and composition must be evaluated against plant design specifications.

3. CORE FEATURES

HeavyDuty Jaw Crusher | Technical Basis: Manganese steel jaws with optimized nip angle | Operational Benefit: Handles large, irregular slag lumps without bridging; withstands extreme abrasion | ROI Impact: Reduces primary stage downtime by up to 40%, lowering maintenance labor and parts costs.

Integrated Magnetic Separation System | Technical Basis: Multiple stages of electro/permanent magnets at critical transfer points | Operational Benefit: Maximizes ferrous metal recovery directly during material flow | ROI Impact: Increases metal yield revenue by capturing an additional 515% of residual ferrous content often missed in singlestage systems.

Centralized PLC Control System | Technical Basis: Automated process control with load monitoring and fault diagnostics | Operational Benefit: Enables singleoperator oversight of entire crushing circuit; prevents equipment damage due to overloads | ROI Impact: Lowers manpower requirements and eliminates costly motor/gear failures due to tramp metal or blockages.

AbrasionResistant Conveying Circuit | Technical Basis: AR400 steel liners, impact beds, and sealedforlife bearings on conveyors | Operational Benefit: Dramatically extends belt and component life in highwear transfer zones | ROI Impact: Cuts annual conveyor maintenance costs by an average of 30% compared to standard systems.

Dust Suppression & Containment | Technical Basis: Pressurized water spray nozzles at crusher inlets/vibrating screens with enclosure panels | Operational Benefit: Effectively controls airborne particulate at source | ROI Impact: Ensures environmental compliance avoids fines reduces housekeeping labor protects worker health.

Modular SkidMounted Design (Optional) | Technical Basis: Preassembled modules on structural skids| Operational Benefit: Significantly reduces onsite civil work installation time commissioning period| ROI Impact Cuts total project installation costs by up to 25% gets your operation generating revenue weeks faster

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Our Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Metallic Recovery Rate | Singlestage magnetic separation after primary crush. | Multistage magnetic separation before after each crushing stage.| +1218% more metal recovered |
| Liner Wear Life (Primary)| Standard manganese jaws replaced every 46 months.| Proprietary alloy composition heat treatment.| +6080% extended service life |
| System Uptime Availability| ~80%, factoring in unplanned stops for clearing cleaning.| >92%, achieved via robust design automated protection.| +15% increase in productive hours |
| Power Consumption per Ton| Fixedspeed drives across all motors.| Configured with variable frequency drives (VFDs) on feeders conveyors.| 1015% lower energy cost |
| Installation & Commissioning| 812 weeks field assembly wiring.| 46 weeks for skidmounted modular plants.| ~50% faster deployment |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to over 300 TPH throughput.
Feed Size: Accepts lump slag up to 1000mm edge length.
Final Product Size: Adjustable output from 20mm to 50mm based on screen configuration.
Power Requirements: Total connected load from 150 kW to 800 kW depending on plant size; supplied at 415V/50Hz or customized voltage/frequency.
Key Material Specifications:
Crusher Jaws/Liners: Premium Manganese Steel / HighChrome Iron Alloy
Chassis/Skids: Heavyduty structural steel (IS 2062)
Conveyor Belting: Minimum EP400/3 with abrasionresistant top cover
Physical Dimensions (for typical 100 TPH skid plant): Approx. Length 25m x Width 8m x Height 6m (excluding feed hopper).
Environmental Operating Range: Designed for ambient temperatures from 10°C to +45°C dustladen environments includes provisions for dust extraction system connection

6. APPLICATION SCENARIOS

Integrated Steel Plant Blast Furnace Slag Processing Challenge Significant downtime on aging primary crusher causing upstream BF granulation pit overflow inconsistent product size affecting sales Solution Replacement with a turnkey Slag Crusher Plant featuring heavyduty primary impactor multistage magnetic separation automated control Results Achieved consistent throughput of120 TPH product sizing within spec increased metal recovery by15 tons per month eliminated unplanned downtime events

MiniMill Electric Arc Furnace (EAF) Slag Challenge Need for compact footprint solution limited space high dust generation creating compliance issues manual handling was laborintensive Solution Installation of a modular skidmounted Slag Crusher Plant with integrated dust suppression enclosures Results Plant operational within5 weeks of delivery dust emissions reduced below permissible exposure limits(PEL) labor requirement cut from3 shifts to1 shift oversight

Copper Smelter Slag Recovery Challenge Processing complex slag containing residual copper matte requiring careful handling achieve specific granulometry for further mineral processing Solution Customdesigned Slag Crusher Plant with specialized liner alloys slower crushing speeds minimize fines generation enhanced ventilation at transfer points Results Optimized particle size distribution increased copper concentrate grade in downstream flotation circuit improved working environment through better dust control

7 COMMERCIAL CONSIDERATIONS

Our Slag Crusher Plants are offered in three primary tiers:

1. Standard Configuration A costeffective solution covering core crushing screening basic magnetic separation ideal for welldefined consistent feed materials
2 Advanced Configuration Includes multistage VFDs advanced PLC automation highergrade wear materials recommended for maximum uptime complex feed
3 Custom Engineered Solutions Tailored layouts special material handling requirements integration with existing granulation or sorting systems

Optional Features Upgrades include:
• Metal Detectors NonFerrous Recovery Systems(Eddy Current Separators)
• Advanced Baghouse Dust Collection Systems
• Remote Monitoring IoT Data Logging Packages
• Extended Warranty Coverage Critical Components

Service Support We offer comprehensive packages:
• Annual Maintenance Contracts(AMC)with scheduled inspections parts discounts
• OnDemand Field Service Technician Support
• Wear Parts Kits ensuring optimal inventory levels

Financing Options Available through partner institutions include:
• Equipment Leasing Structures
• Term Loans
• RenttoOwn Programs

Request a detailed quotation based on your specific annual tonnage feed characteristics site layout required final product specifications

FAQ – SLAG CRUSHER PLANT SOLUTIONS

Q1 What are the key factors determining the right capacity size?
The primary factors are your daily monthly slag generation volume required final product size needed metallic recovery rate A detailed analysis of your feedstock including lump size distribution hardness metallic content ensures correct sizing

Q2 How does this plant integrate with our existing material handling system?
Our engineering team will review your current conveyor layouts feed discharge points We design transition hoppers chutes interface conveyors ensure seamless integration minimal disruption during installation Electrical controls can be adapted match your existing PLC network protocols

Q3 What is the expected operational lifespan major components?
With proper maintenance industry data shows core structural components last15+ years Major crushers screens have10+ year design life Wear parts like jaw liners impact hammers screen meshes are consumables their lifespan depends directly on throughput material abrasiveness typically ranging from6 months24 months

Q4 Can you provide performance guarantees?
Yes Our proposals include guaranteed minimum throughput capacity under defined conditions guaranteed final product gradation We stand behind our equipment performance these metrics are contractually stipulated based on preagreed feedstock samples analysis

Q5 What does typical installation commissioning involve?
For skidmounted plants it involves site preparation foundation bolting electrical power cable connection For stationary plants it includes more extensive civil work Our team provides supervision commissioning support operator training We manage the process until plant acceptance signoff