1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
Low Throughput & High Downtime: Inefficient primary crushing and frequent clogging from uncrushable material halt your entire processing line, costing thousands per hour in lost production and labor.
Excessive Wear & Maintenance Costs: Standard crushers rapidly deteriorate when processing highly abrasive slag, leading to premature failure of liners, hammers, and rotors. The resulting parts replacement and unplanned maintenance erode your profit margins.
Inconsistent Final Product Size: Poorly controlled crushing results in uneven aggregate size distribution, reducing the market value of your slag product and limiting its application in highspecification construction or cement blending.
High Operational Complexity & Risk: Reliance on multiple, nonintegrated units for feeding, crushing, screening, and metal recovery increases manpower needs, safety hazards, and points of potential failure.

Is your current setup delivering the reliable throughput and product quality required for profitability? The solution lies in a purposeengineered slag crusher plant processing plant.

2. PRODUCT OVERVIEW

A slag crusher plant processing plant is a stationary or semimobile integrated system designed specifically for the reduction, screening, and separation of metallurgical slag (blast furnace, steel furnace). It transforms large, irregular slag feed into precisely graded aggregates for sale or further use.

Operational Workflow:
1. Primary Receiving & PreScreening: Runofpile slag is fed via loader into a robust hopper with a grizzly section to bypass fine material.
2. Primary & Secondary Size Reduction: A heavyduty jaw crusher performs initial breaking. A secondary impactor or cone crusher then reduces the material to the target size range.
3. Material Screening & Classification: Vibrating screens separate crushed material into specified product fractions (e.g., 05mm, 510mm, 1020mm).
4. Metal Recovery (Optional): Overband magnets or magnetic head pulleys extract remaining ferrous metal from the crushed stream for recycling revenue.
5. Stockpiling & Dispatch: Graded aggregates are conveyed to designated stockpiles for loadout.

Application Scope: Processing blast furnace slag (BFS), steel slag (LD slag), ferroalloy slag, and other nonmetallic mineral aggregates.
Key Limitation: Not designed for primary rock mining or processing extremely hard virgin rock; optimal performance requires feed material within specified hardness (Mohs scale) and size parameters.

3. CORE FEATURES

HeavyDuty Reciprocating Plate Feeder | Technical Basis: Controlled volumetric flow with adjustable stroke | Operational Benefit: Ensures even, chokefree material delivery to the primary crusher, preventing surges and overloads | ROI Impact: Eliminates crusher stalls; increases overall plant throughput by up to 25% versus vibratory feeders in sticky slag conditions.

Manganese Steel Crusher Liners | Technical Basis: Workhardening austenitic manganese steel construction | Operational Benefit: Liners gain hardness upon impact, dramatically extending service life under severe abrasion | ROI Impact: Reduces liner replacement frequency by 4060%, lowering parts inventory costs and maintenance downtime.

Integrated Metal Separation System | Technical Basis: Permanent overband magnet with selfcleaning belt | Operational Benefit: Automatically recovers residual tramp metal during processing | ROI Impact: Generates ancillary revenue from scrap metal; protects downstream crushers from damage; improves final product purity.

Centralized PLC Control System | Technical Basis: Programmable Logic Controller with humanmachine interface (HMI) panel | Operational Benefit: Allows singleoperator monitoring and control of entire plant flow from a protected cabin | ROI Impact: Reduces labor requirements; enables quick troubleshooting; provides production data for efficiency analysis.

Modular SkidMounted Design | Technical Basis: Preassembled structural steel skids for major components | Operational Benefit: Significantly reduces onsite civil work and installation time | ROI Impact: Cuts installation costs by approximately 30% and allows for potential relocation or plant expansion.

HeavyDuty Vibrating Screens with Deck Guards | Technical Basis: HighG force exciters and easily replaceable deck panels | Operational Benefit: Provides consistent sizing efficiency even with damp or fine slag materials; guards contain fly rock | ROI Impact: Ensures onspec product yield exceeding 95%, maximizing sales value; enhances operator safety.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Basic Crushing Circuit) | Our Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| System Uptime| ~7580% (frequent stops for clearing,jams) |>92% (engineered flow control) |>15% Improvement |
| Liner Life in Primary Crusher| 6090 days (standard manganese) |>180 days (premium/workhardening) |>100% Improvement |
| Tons Processed per ManHour| Lower due to multipoint operation |>25% higher (centralized control) |>25% Improvement |
| Metal Recovery Rate| Manual picking or basic magnet |>99% ferrous recovery (optimized placement) |>30% Improvement in purity/revenue |
| Installation & Commissioning Time| 812 weeks (field assembly) |>57 weeks (modular skid design) |>~40% Reduction |

5. TECHNICAL SPECIFICATIONS

Processing Capacity: Configurable from 50 to over 300 tons per hour (TPH).
Power Requirements: Total connected load typically ranges from 150 kW to 450 kW depending on plant configuration; supplied at 415V/50Hz or customized.
Material Specifications: Fabricated from S355JR structural steel; critical wear components in AR400 abrasionresistant steel and Grade I manganese steel.
Primary Crusher Options: Jaw Crusher sizes from 750x500mm up to 1200x1000mm feed opening.
Secondary Crusher Options: Impact Crusher (for less abrasive BFS) up to Ø1400mm rotor diameter, or Cone Crusher (for highly abrasive steel slag).
Screen Specifications: Single or doubledeck vibrating screens from 1800x4800mm up to 2400x6000mm.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression spray systems are standard.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Slag Processing Yard Challenge:

A major steel producer was landfilling LD converter slag due to an inefficient old crushing circuit that produced inconsistent aggregate sizes and suffered constant hammer wear in the impactor.

Solution:

Implementation of a turnkey slag crusher plant processing plant featuring a deepchamber jaw crusher for primary reduction followed by a robust cone crusher for secondary crushing. A twostage screening system was integrated with powerful overband magnets.

Results:

The plant achieved a consistent product yield of over 200 TPH of highvalue aggregate sold to the local cement industry. Metal recovery increased revenue by an additional $50k annually. Planned maintenance intervals extended from monthly to quarterly.

Independent Aggregate Producer – Diversification

Challenge:
A traditional quarry operator sought to diversify into industrial byproduct processing but needed a system capable of handling highly variable feed sizes without constant reconfiguration.

Solution:

A semimobile slag crusher plant on skids with a heavyduty apron feeder was selected alongside an impact crusher with hydraulic adjustment for quick product size changes.

Results:

The operator could now process both purchased demolition concrete and sourced steelworks slag using one flexible unit. Changeover between materials takes less than two hours through hydraulic settings adjustments only.

7. COMMERCIAL CONSIDERATIONS

Our solutions are offered across three tiers:

1. Standard Configuration Plant ($250k $500k):
Includes core modules—feeder, primary jaw crusher,vibrating screen,and conveyors—for basic sizing operations.Optional features include magnetic separator,dust suppression kit,and starter motor controls package.Service package includes commissioning plus oneyear parts warranty.

2.
3.Enhanced Recovery Plant ($500k $900k):
Adds secondary cone/impactor crushers,a multideck sizing screen,and automated metal separation systems.Optional features include finished product washing systems,tramp iron protection devices,and advanced PLC automation.Service package extends warranty coverage plus annual preventive maintenance inspections.Financing options available through partner institutions include equipment leasing plans starting at $8k/month.

4.Turnkey Processing Facility ($900k+):
Fully integrated system including receiving hoppers,surge bins,total dust collection enclosure,and automated weighloading out system.Custom engineering available.Optional features include remote monitoring via SCADA systems.Service package includes full operational training,a dedicated service manager,and guaranteed spare parts delivery within agreed terms.Comprehensive project financing can be structured based on client credit profile.

\Financing terms subject to credit approval.Please inquire directly regarding current rates.

FAQ

1.Q:What types of raw feed size can your standard plants accept?
A:The standard primary jaw configuration accepts feed lumps up to ~650mm edge length.Larger inlet sizes are available as an option.Precrushing may be advised if runofpile chunks exceed this dimension consistently

2.Q:What is the typical lead time between order placement commissioning?
A.For standard configurations lead time is typically between16and24weeks.This covers manufacturing,factory testing,and shipment.Modular skid design reduces site installation time significantly compared traditional builtinplace plants

3.Q:What ongoing maintenance does this equipment require?
A.Daily visual inspections weekly greasing checks are required.Major planned maintenance involves periodic liner replacements based actual wear rates which we help predict using historical field data.A comprehensive preventive schedule provided

4.Q.How does this integrate with our existing conveyor stockpile system?
A.The plants are designed as complete circuits but can be adapted tie into existing infrastructure.We require details regarding existing conveyor heights capacities ensure proper interface engineering during design phase

5.Q.What kind power supply needed operate typical200TPHplant?
A.A200TPHslag crushing screening circuit typically requires total connected load approximately300kW.We recommend consulting local electrical engineer ensure adequate supply transformer capacity softstart systems minimize grid disturbance

6.Q.Are spare parts readily available long after purchase?
A.All critical wear parts common consumables stocked our central warehouse.We provide recommended initial spare parts list order ensure minimal downtime guarantee availability support throughout equipment lifecycle

7.Q.What aftersales service support included?
A.All installations include commissioning supervision operator training period.We offer tiered service contracts ranging emergency breakdown support scheduled preventive maintenance visits full annual inspection programs