1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with significant hidden costs. Are you facing these operational challenges?
High Downtime for Primary Crushers: Oversized, uncrushable metallic “tramp” material in slag jams primary crushers, leading to hours of unplanned downtime for manual clearing and causing premature wear on mantles and concaves.
Inefficient Material Recovery: Inconsistent particle size output from aging equipment results in poor liberation of valuable metals, leaving profit trapped in your waste stream and reducing the quality of your aggregate product.
Excessive Maintenance Costs & Safety Risks: Frequent breakdowns of underengineered crushers not only drive up parts and labor costs but also increase the exposure of maintenance teams to hazardous environments during repairs.
Low Throughput Capacity: A plant designed for theoretical capacity often falters under realworld conditions of variable feed size and hardness, failing to keep pace with upstream production and creating storage pile headaches.

What if your slag processing line could operate with predictable availability, maximize metal recovery, and turn a cost center into a consistent revenue stream? The foundation of this shift is a purposebuilt slag crusher plant.

2. PRODUCT OVERVIEW

A slag crusher plant is a stationary or semimobile crushing circuit specifically engineered to process metallurgical slag from blast furnaces or steel mills. Its design prioritizes durability against abrasive material and resilience to shock loads from metallic inclusions.

Operational Workflow:
1. Primary Crushing & Tramp Metal Removal: Large slag feed (up to ~1000mm) is reduced by a robust primary crusher (e.g., jaw crusher). An integrated tramp metal detection and removal system protects downstream equipment.
2. Secondary Crushing & Screening: Material is further reduced in a secondary crusher (e.g., cone or impactor) to liberate encapsulated metals. A screen deck separates material into specified size fractions.
3. Metal Recovery & Final Sizing: Liberated ferrous metal is extracted via magnetic separators. The remaining aggregate may be directed to tertiary crushing for producing specific, highvalue gradations.

Application Scope: Ideal for integrated steel plants, standalone slag processing contractors, and aggregate producers specializing in industrial byproducts.
Limitations: Not designed for primary ore processing or extremely soft, nonabrasive materials. Feed material chemistry should be evaluated for equipment alloy recommendations.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: Reinforced frame, hightensile steel castings, and oversized bearings | Operational Benefit: Sustains shock loads from uncrushable metals with minimal deformation; enables continued operation while scheduling planned removal | ROI Impact: Reduces catastrophic failure risk by an estimated 60%, protecting the highest capital component in your line.

Integrated Tramp Metal Protection | Technical Basis: Hydraulic release or overload protection system paired with suspended plate magnets or metal detectors | Operational Benefit: Automatically disgorges tramp iron or reverses to clear jammed cavities without manual intervention | ROI Impact: Field data shows up to 80% reduction in unplanned downtime related to tramp metal incidents.

AbrasionResistant Material Flow Path | Technical Basis: AR400/500 steel liners at all impact points, ceramic wear tiles in highabrasion zones | Operational Benefit: Liners withstand the continuous abrasive action of slag, maintaining crushing chamber geometry for consistent output | ROI Impact: Extends liner life by 4060% compared to standard manganese steel, lowering consumable cost per ton.

HighEfficiency Magnetic Separation Stage | Technical Basis: Selfcleaning crossbelt magnets or drum separators with optimized field strength and positioning | Operational Benefit: Maximizes recovery of liberated ferrous metal directly from the crushed stream, producing a cleaner aggregate product | ROI Impact: Increases metal recovery revenue; industry testing demonstrates capture rates exceeding 98% of liberated ferrous content.

Centralized PLC Automation & Monitoring | Technical Basis: Programmable Logic Controller with HMI interface monitoring power draw, oil flow/temperature, and production rates | Operational Benefit: Operators can optimize feed rates for efficiency and receive early fault diagnostics to schedule maintenance | ROI Impact: Prevents secondary damage from undetected issues; improves overall plant throughput predictability.

Modular SkidMounted Design (Optional) | Technical Basis: Preassembled units with integrated walkways, ladders, and electrical connections | Operational Benefit: Dramatically reduces site installation time and civil work costs; facilitates future relocation if needed | ROI Impact: Can reduce commissioning timeline by up to 70%, accelerating timetoproduction.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Our Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Plant Availability (Scheduled Uptime) | 8085%, frequent tramp metal stops | 9295%, with automated protection systems| +10% (approx.) |
| Liner Life in Primary Stage (Abrasive Slag) | ~40,000 MT throughput per set| ~65,000 MT throughput per set| +62% |
| Metal Recovery Purity (Ferrous Fraction)| 9094% purity due to poor liberation| 9799% purity via optimized crushing stages| +58% |
| Energy Consumption per Ton Processed| Baseline (100%) for older plant designs| Estimated 8590% via efficient drive systems & optimal load management| 10% to 15% |
| Installation & Commissioning Period| 812 weeks for traditional foundationbased plants| 35 weeks for preassembled skid design| ~60% reduction |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to over 300 TPH processed slag.
Primary Crusher Options: Jaw Crusher (Feed size up to 1000mm) or HeavyDuty Impact Crusher.
Power Requirements: Total installed power typically ranges from 250 kW to 800 kW depending on configuration; supplied for 50Hz or 60Hz operation.
Key Material Specifications: Primary frame – Fabricated heavy steel plate; Liners – AR400/500 Steel or equivalent; Critical shafts – Alloy steel forgings.
Physical Dimensions (Sample Skid): Varies by capacity; e.g., a 150 TPH primary skid may measure approx. L12m x W4m x H5m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system compliant with standard enclosure requirements.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Modernization

Challenge: A major steel producer faced chronic downtime in its aging slag crushing line due to tramp metal jams every two weeks on average. Metal recovery was suboptimal due to poor particle size control.
Solution: Implementation of a turnkey slag crusher plant featuring a jaw crusher with hydraulic toggle release system followed by secondary cone crushing and twostage magnetic separation.
Results: Unplanned stoppages fell by over 85%. Recovered ferrous metal yield increased by an estimated ₹1 crore annually based on volume pricing at the time of reporting.

Independent Slag Processing Contractor

Challenge: A contractor needed scalable capacity across multiple client sites but was constrained by high mobilization costs and lengthy setup times using traditional equipment setups.
Solution: Deployment of two semimobile skidmounted modular plants designed around our core features list above.
Results:The contractor reduced site commissioning time from eight weeks down three weeks per location.This flexibility allowed them secure two additional contracts within same fiscal year increasing overall business volume

Construction Aggregate Producer

Challenge:Aggregate producer sought diversify product line incorporating processed BOF slag highquality road base material but required consistent minus mm specification
Solution:A custom configured three stage including tertiary vertical shaft impactor VSI fine shaping chamber ensure cubical final product
Results:The producer successfully marketed premium specification aggregate achieving price point higher than conventional crushed stone while utilizing lower cost raw feedstock

7.COMMERCIAL CONSIDERATIONS

Pricing tiers are determined primarily by required throughput capacity robustness desired features:
Tier Basic Configuration TPH range includes primary crushing basic screening magnetic separation suitable straightforward applications where feed relatively homogenous
Tier Advanced Configuration TPH range adds secondary crushing advanced automation controls enhanced dust suppression recommended variable feed composition maximum metal recovery
Tier Custom High Volume Systems TPH engineered specific site constraints extreme abrasion resistance requirements

Optional Features Include:
Dust Suppression Cannon Systems Enclosed Conveyor Gallery Automated Greasing Systems Remote Monitoring Telematics Advanced Particle Size Analysis Feedback Loop

Service Packages Available:
Standard Warranty Parts Support Onsite Training Extended Service Agreements Including Scheduled Inspections Wear Parts Kits Guaranteed Response Times For Critical Breakdowns

Financing Options:
We work established financial partners offer competitive leasing rental purchase plans including operating lease structures help manage capital expenditure

8.FAQ

What preliminary data required configure optimal plant?
Provide details average daily monthly volume typical maximum feed size analysis metallic content hardness abrasion index desired final product sizes This allows us engineer most efficient circuit

How does plant handle "hot" slag?
While not designed process molten material we can incorporate special feed hoppers air cooling baffles heat resistant components certain conveyor sections handle solidified but still elevated temperature material Specific temperature limits must defined during engineering phase

What ongoing operational costs should budget?
Primary consumables are wear liners electricity spare parts like conveyor belts rollers Regular maintenance following prescribed schedule key controlling long term operating expense We provide detailed cost per ton estimate based your specific parameters

Are spare parts readily available internationally?
Yes We maintain standardized inventory critical wear parts components Our global logistics network ensures timely delivery supported local service partners many regions Documentation includes detailed part numbers cross references simplify ordering process

Can existing equipment integrated into new plant design?
Often yes Existing screens conveyors magnetic separators can sometimes incorporated new layout during design phase audit will assess condition compatibility control systems determine feasibility integration