1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with significant hidden costs. Are you facing these common operational challenges?
High Downtime for Primary Crushers: Oversized, uncrushable metallic remnants ("tramp metal") in slag feed cause frequent jams and damage to primary crushing jaws, leading to hours of unplanned maintenance and lost throughput.
Inefficient Material Separation: Inadequate liberation of metal from slag conglomerates results in valuable metal loss to waste stockpiles and contaminated aggregate product, directly impacting revenue and product quality.
Excessive Wear & Maintenance Costs: The highly abrasive nature of slag rapidly degrades standard crusher liners and components, creating a cycle of high spare parts consumption and laborintensive changeouts that erode profit margins.
Inconsistent Final Product Size: Without precise control over the crushing circuit, achieving a consistent, marketable aggregate size is difficult, leading to product rejection or the need for costly reprocessing.

Is your current setup causing unpredictable downtime, wasting recoverable metal, and driving up your cost per ton? A purposeengineered slag crusher plant is the systematic solution.

2. PRODUCT OVERVIEW

A slag crusher plant is a integrated processing system designed specifically for the size reduction and metal recovery of metallurgical slag (blast furnace, steel furnace, etc.). It transforms raw, variablesized slag into a valuable, graded aggregate while maximizing the extraction of residual metallic content.

Operational Workflow:
1. Primary Crushing & Screening: Large slag feed (up to ~800mm) is reduced by a robust primary crusher (typically a jaw crusher). An initial scalping screen removes fine material.
2. Metal Separation & Recovery: The crushed material passes over magnetic separators (suspended drum or overhead magnetic) to extract ferrous metal. An eddy current separator may be incorporated for nonferrous recovery.
3. Secondary Crushing & Grading: The demetalized slag undergoes secondary crushing (often via cone or impact crusher) and is precisely screened into commercial aggregate fractions (e.g., 05mm, 510mm, 1020mm).

Application Scope: Designed for integrated steel plants, standalone slag processing yards, and aggregate producers handling metallurgical byproducts.
Limitations: Not suitable for processing molten slag or as a primary ore processing plant. Feed material size and hardness must be within the plant's engineered design specifications.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: Reinforced manganese steel jaws & oversized bearings | Operational Benefit: Handles large slab slag and occasional tramp metal with minimal risk of catastrophic failure | ROI Impact: Reduces unexpected breakdowns by up to 60%, protecting downstream equipment and ensuring continuous feed

Integrated Magnetic Separation Circuit | Technical Basis: Highintensity permanent magnetic drums installed at key transfer points | Operational Benefit: Recovers >95% of liberated ferrous metal directly from the crushing stream | ROI Impact: Turns waste into revenue; recovered metal often offsets operational costs significantly

AbrasionResistant Linings & Components | Technical Basis: AR400/500 steel liners in hoppers, chutes, and screens; specialized alloy crusher wear parts | Operational Benefit: Extends service life in highly abrasive environments by 23x compared to standard materials | ROI Impact: Lowers costperton for wear parts and reduces maintenance labor hours

Centralized PLC Control System | Technical Basis: Automated process control with touchscreen HMI for monitoring motor loads, conveyor speeds, and bin levels | Operational Benefit: Enables oneoperator oversight of the entire circuit for startup, shutdown, and troubleshooting | ROI Impact: Optimizes power consumption and improves overall plant availability through proactive monitoring

Modular SkidMounted Design | Technical Basis: Preassembled modules for primary crushing, screening, and separation on structural steel frames | Operational Benefit: Dramatically reduces site installation time and civil work requirements | ROI Impact: Faster commissioning (weeks vs. months), leading to quicker return on investment

Dust Suppression System | Technical Basis: Strategically placed spray nozzles at crusher discharge and transfer points with solenoid valve control | Operational Benefit: Maintains regulatory compliance for particulate emissions while minimizing water usage on processed material | ROI Impact: Avoids fines from environmental agencies and prevents product degradation from excess moisture

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Basic Crushing Plant) | Our Slag Crusher Plant Solution | Advantage (% improvement) |
| : | : | : | : |
| Metal Recovery Rate (Ferrous) | 95% (active multistage separation)| +18% more revenue from scrap |
| Liner Life in Primary Crusher| ~40,000 tons (standard manganese)| ~100,000 tons (specialized alloy)| +150% longer service life |
| Plant Availability / Uptime| ~75% (frequent jams/cleanouts)| >92% (engineered feed & protection)| +22% more productive hours |
| Finished Product Consistency| ±15% variance on grade sizing| ±5% variance on grade sizing| +66% more precise grading |
| Installation & Commissioning Time| 46 months (fieldbuilt foundations)| 68 weeks (skidmounted modular)| ~70% faster deployment |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to 300 TPH throughput.
Power Requirements: Total connected load typically between 250 kW 800 kW depending on configuration; supplied at 415V/50Hz or as per regional standard.
Material Specifications: Primary structure: IS 2062 mild steel; Abrasive contact areas: Minimum AR400 steel plate; Crusher wear parts: Highgrade manganese steel or equivalent chromium alloy.
Physical Dimensions (Typical 150 TPH Plant): Approximate footprint of 40m L x 20m W x 15m H. Modular design allows for flexible layout adaptation.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C with appropriate lubrication systems. Dust suppression system maintains operation within local emission standards.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Recycling

Challenge:A major steel producer was landfilling LD slag due to inefficient metal recovery (<70%) using mobile equipment. The inconsistent aggregate produced had limited market value.
Solution:A turnkey slag crusher plant with a powerful jaw crusher for large converter slabs followed by two stages of magnetic separation was installed at their captive slag yard.
Results:Metal recovery increased to over 96%. The plant produces over 120 TPH of highpurity construction aggregate meeting national road standards. Landfill costs were eliminated entirely within 14 months.

Independent Aggregate Producer Processing Imported Slag

Challenge:A construction material supplier processing purchased metallurgical slag faced excessive wear costs in their existing limestone crushing circuit and poor product quality due to residual metals.
Solution:A dedicated secondarystage slag crusher plant, focusing on fine crushing/screening with integrated eddy current separation was installed parallel to their main line specifically for preprocessed slag feed.
Results:Aggregate product contamination fell below required specifications (<0.5% free metal). Wear part costs specific to the slag line dropped by over half due to appropriate material selection.

7. COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are based on capacity rating:
Standard Range Plants (~50100 TPH): Costeffective solution focused on core crushing/magnetic separation functions using proven components.
HighCapacity Plants (~100200 TPH): Includes advanced features like automated tramp release systems on primary crushers,
dual vibration screens,
PLC automation,
comprehensive dust control,
multiple magnetic separators,
optional nonferrous recovery modules,
extended warranty packages covering major mechanical components,
annual preventive maintenance contracts including wear part inspections,
financing options available through partner institutions including leasetoown structures which can preserve capital expenditure budgets,

8.FAQ

Q1.Is this plant compatible with our existing conveyor system?
A.The modular design allows us to engineer transfer points that interface with your existing infrastructure.Field measurements are taken during the planning phase to ensure compatibility regarding height discharge rates,and belt widths.

Q2.What level of operator training is required?
A.Comprehensive training is provided covering normal operation startup/shutdown sequences basic troubleshooting,and safety procedures Most plants are designed for intuitive operation via the central PLC panel reducing the learning curve significantly.

Q3.How does this impact our overall operational costs?
A.Field data shows that while capital investment is required,the significant reduction in unplanned downtime lower wear part consumption,and new revenue streams from recovered metal typically deliver an ROI within years depending on your throughput volume,

Q4.What are typical delivery lead times?
A.For standard configuration plants lead time ranges from weeks following final engineering approval Custom configurations may require additional time Detailed project schedules are provided upon order confirmation,

Q5.Do you provide performance guarantees?
A.We provide guaranteed minimum throughput capacity under defined feed conditions as well as guaranteed minimum ferrous metal recovery rates These are detailed in commercial contracts,

Q6.Can we process other materials like construction waste with this plant?
A.The core design is optimized specifically for highly abrasive metallurgical slags While it can process hard rock it may not be optimal For mixed waste streams we recommend a separate analysis,

Q7.What aftersales support is available?
A.We offer tiered service packages ranging from remote technical support only up through comprehensive annual maintenance contracts which include scheduled inspections spare parts discounts,and priority field service response