1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
Unreliable Throughput: Inconsistent feed size and hard, abrasive materials cause frequent jams in standard crushers, leading to unplanned downtime that halts downstream processing.
Excessive Wear Costs: The highly abrasive nature of slag rapidly degrades standard manganese steel components, resulting in unsustainable expenses for wear parts and labor for changes.
Inefficient Liberation: Inadequate crushing fails to fully liberate metallic content from the slag matrix, causing valuable material to report to waste and reducing overall recovery rates.
High Maintenance Complexity: Equipment not purposebuilt for this duty cycle requires constant attention, diverting skilled technicians from preventive tasks and increasing mean time to repair (MTTR).
Footprint & Integration Issues: Can your current material handling flow accommodate another piece of equipment without a major plant redesign?

The core question is: how do you transform this challenging byproduct into a consistent, profitable stream while controlling operational costs? A dedicated slag crusher plant provides the engineered solution.

2. PRODUCT OVERVIEW

A private label slag crusher plant is a turnkey system engineered specifically for the primary and secondary reduction of metallurgical slag (blast furnace, steel furnace, ferroalloy). It processes large, irregular slag dumps or tapped slag into a calibrated aggregate or feedstock for further metal recovery.

Operational Workflow:
1. Feed & PreScreening: Runofpile slag is fed via loader or conveyor. An optional initial grizzly screen removes fine undersize material to bypass the crusher, increasing system efficiency.
2. Primary Crushing: A heavyduty jaw crusher or impact breaker reduces large slabs (up to 1000mm+) to a manageable size (typically under 200mm), applying high inertia force to break along natural cleavage lines.
3. Metal Separation: The crushed material passes over an overhead magnetic separator (drum or crossbelt) to extract liberated ferrous metal for recycling.
4. Secondary Crushing & Sizing: A cone crusher or impactor provides final reduction in a closed circuit with a vibrating screen to produce precisely sized fractions (e.g., 05mm, 520mm, 2040mm).
5. Stockpiling: Sized aggregates are conveyed to designated stockpiles for sale as construction aggregate or further processing.

Application Scope & Limitations:
Scope: Ideal for integrated steel plants, standalone smelters, slag processing yards, and aggregate producers handling ferrous and nonferrous slags.
Limitations: Not designed for primary ore processing or extremely soft, nonabrasive materials. System output is contingent on feed size consistency and material characteristics (abrasion index).

3. CORE FEATURES

HeavyDuty Jaw Crusher | Technical Basis: Deep crushing chamber & optimized nip angle | Operational Benefit: Handles large slab feed without bridging; high reduction ratio minimizes secondary stage load | ROI Impact: Reduces primary stage energy consumption by up to 18% versus nonoptimized designs.

AbrasionResistant Liner Package | Technical Basis: Bimetallic composite castings with highchrome inserts in critical wear zones | Operational Benefit: Extends service life of wear parts by 23x compared to standard manganese steel | ROI Impact: Lowers costperton for wear components and reduces changeout frequency by over 60%.

Integrated Magnetic Separation Circuit | Technical Basis: Permanent magnet drum separator installed at optimal discharge point | Operational Benefit: Recovers liberated tramp metal continuously during operation, protecting downstream conveyors and crushers | ROI Impact: Captures additional revenue stream from scrap metal; prevents costly damage to secondary crushers.

PLCBased Control & Monitoring System | Technical Basis: Centralized automation with load management and fault diagnostics | Operational Benefit: Allows singleoperator control; provides realtime data on power draw, throughput, and fault alerts | ROI Impact: Optimizes production rates; reduces labor requirements and diagnostic time by approximately 30%.

Modular SkidMounted Design | Technical Basis: Preassembled modules on heavyduty Ibeam skids | Operational Benefit: Significantly reduces site installation time and civil work costs; simplifies future relocation if needed | ROI Impact: Cuts installation time by up to 40%, accelerating timetoproduction.

HeavyDuty Vibrating Grizzly Feeder | Technical Basis: Robust deck construction with replaceable liners and high Gforce capability | Operational Benefit: Ensures consistent feed rate to the primary crusher while scalping out fines; absorbs direct dump impacts from loaders | ROI Impact: Maximizes primary crusher utilization and prevents costly damage from erratic feeding.

Enclosed Conveying with Dust Suppression Points| Technical Basis: Belt conveyors with fulllength skirting and strategically placed spray nozzles| Operational Benefit: Contains fugitive dust at transfer points, maintaining a safer site environment and reducing product loss| ROI Impact: Minimizes water usage compared to fullarea spraying; helps ensure compliance with site environmental regulations.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Private Label Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Wear Part Life (Primary) | Standard Manganese Steel Liners | BiMetallic Composite Liners with Chrome Inserts| +150% |
| System Uptime Availability| ~8085% (due to jams/wear) |>92% (engineered flow & components)| +1015% |
| Metal Recovery Efficiency| Postcrush magnetic separation only| Inline primary & secondary magnetic separation stages| +25% recovery yield |
| Installation & Commissioning Time| Fieldfabricated foundations & assembly| Preassembled modular skid design|40% time |
| Specific Power Consumption(kWh/ton)| Varies widely with feed size inconsistency| Optimized circuit with loadsensing drives|15% average |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to over 300 TPH of processed slag.
Feed Size Maximum: Up to 1000mm x 1200mm slab input.
Final Product Sizing: Adjustable via screen selection; typical ranges from 05mm sand substitute up to 40mm aggregate.
Power Requirements: Total connected load from 150 kW to 600 kW depending on configuration; standard supply at 415V/50Hz/3Phase (other voltages available).
Material Specifications: Primary frame constructed from heavyduty structural steel (S355JR). Critical wear components use HARDOX or equivalent abrasionresistant steel. Crusher jaws/liners in premium manganese or composite alloys.
Physical Dimensions (Typical Setup): Approximate footprint of 35m (L) x 18m (W). Overall height varies but typically under 10m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust suppression system rated for operation where water is available.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Recycling

Challenge: A major steel producer faced escalating landfill costs for blast furnace slag and needed reliable sizing of material for road base sales while recovering residual iron.
Solution: Implementation of a turnkey private label slag crushing plant featuring a heavyduty jaw crusher followed by two stages of magnetic separation before final screening.
Results: Achieved consistent production of 20mm aggregate meeting local spec; increased metal recovery by 22%; reduced offsite disposal costs by 95%; project payback achieved in under 18 months through product sales.

Ferroalloy Smelter ByProduct Processing

Challenge: A ferrochrome smelter’s existing hammer mill system suffered extreme wear (<200 hours life) on parts due to ultraabrasive slag composition, causing excessive downtime.
Solution: Replacement with a configured private label plant using an impact breaker designed for abrasives in closed circuit with specialized alloy liners throughout the flow path.
Results: Wear part life extended beyond 600 hours per set; system availability increased from 90%; maintenance labor hours dedicated to the crushing circuit were reduced by twothirds.

Independent Aggregate Producer Market Expansion

Challenge: An aggregate company sought entry into the industrial byproducts market but required flexible equipment capable of handling varied feed materials without constant reconfiguration.
Solution: Installation of modular private label plant designed around an impactor as the primary unit allows adjustment between different types of slags without major mechanical changes..
Results: Enabled processing contracts across three different local industries producing varying slags within one fiscal year due reduced changeover times between jobs..

COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around throughput capacity:
• Standard Range (50 –150 TPH): Base configuration includes primary crushing magnetic separation basic screening PLC controls..
• HighCapacity Range (150 –300+ TPH): Includes larger feeders multiple conveyor lines advanced dust suppression highertier automation..
Optional features include:
• Portable wheelmounted chassis..
• Advanced metal detectors nonferrous recovery systems..
• Automated lubrication systems..
• Remote monitoring telemetry packages..
Service packages offered:
• Basic Warranty covering defects parts labor first twelve months operation..
• Extended Support Plans providing scheduled inspections preferential parts pricing technical support hotline access..
Financing options can be discussed including operating leases capital leases leaseto own structures tailored support cash flow requirements facilitate capital approval..

FAQ

What type power supply required operate typical private label slug crushr plnt?
Most configurations require threephase industrial voltage supply typically between kV kVA depending selected capacity Additional transformers may needed consult specifications early planning stages..

How does system handle wet sticky slug conditions common some operations?
Design includes specific features such cascading material flow minimize packing grizzly deck configurations prevent clogging However extremely high moisture content may necessitate predrying blending drier material maintain rated throughput..

What typical lead time delivery commissioning complete plnt?
For standard configurations lead time generally ranges weeks months order confirmation factoring manufacturing shipping Site preparation civil works should commence parallel Modular skid design reduces onsite commissioning period approximately weeks following delivery..

Are spare parts readily available given private label nature equipment?
Yes All critical wearing components use industrystandard interchangeable designs OEM equivalents ensuring multiple sourcing options maintain stock strategic consumables recommended guarantee uptime..

Can existing conveyors other infrastructure integrated new crushr plnt?
Integration possible requires detailed review existing layout capacities Our engineering team can assess provide interface drawings recommendations necessary modifications ensure seamless material handoff..

What metrics used quantify return investment ROI such project?
Key metrics include increased revenue recovered metal sale sized aggregate decreased disposal landfill tipping fees reduced maintenance downtime labor costs combined calculate overall payback period Field data shows typical payback achieved within months based current commodity operating cost structures..