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 composition cause frequent jams and unplanned stoppages, halting downstream processes and delaying material recovery.
Excessive Wear & Maintenance Costs: The abrasive nature of slag rapidly degrades standard crusher components, leading to high spare part consumption, costly labor for replacements, and extended equipment downtime.
Inefficient Size Reduction: Suboptimal crushing results in oversized material that requires reprocessing or fails separation processes, directly reducing metal recovery yield and creating storage inefficiencies.
High Operational Complexity: Equipment requiring constant operator intervention for feed regulation or clearing increases labor costs and introduces potential for human error.

If these issues are impacting your plant’s profitability, the solution lies in a purposeengineered system. A dedicated slag crusher plant is designed to transform this operational liability into a consistent, profitable recovery stream.

2. PRODUCT OVERVIEW

A slag crusher plant is a stationary or semimobile processing system specifically engineered to reduce large chunks of raw slag (from blast furnace, steel furnace, or copper/ferronickel production) into a uniform, graded aggregate. This prepares the material for efficient metal liberation and recovery through subsequent screening and separation stages.

Operational Workflow:
1. Primary Crushing: Large slag feed (up to 1000mm) is reduced to a manageable size (approx. 150200mm) using a robust jaw crusher or impact breaker.
2. Secondary Crushing & Screening: Material is further reduced via a cone crusher or impact crusher and passed over a vibrating screen to separate the target product size.
3. Metal Separation: Oversized material is recirculated (closedcircuit), while correctly sized material passes over magnetic separators to extract ferrous content.
4. Stockpiling: The cleaned, sized aggregate is conveyed to stockpiles for sale or further use.

Application Scope & Limitations:
Scope: Ideal for integrated steel plants, smelters, scrap yards, and independent slag processing contractors handling ferrous and nonferrous slags.
Limitations: Not designed for primary mining ore or extremely soft, nonabrasive materials. System performance is contingent on proper feed regulation and adherence to maximum input size specifications.

3. CORE FEATURES

HeavyDuty Vibrating Feeder | Technical Basis: Controlled volumetric flow with grizzly section | Operational Benefit: Regulates uneven feed from loaders, removes fine undersize material before primary crushing | ROI Impact: Prevents crusher overload and wear, increases primary circuit efficiency by up to 15%

Manganese Steel Crusher Wear Parts | Technical Basis: Workhardening alloy steel construction | Operational Benefit: Components develop a hardened surface through use, extending service life against extreme abrasion | ROI Impact: Reduces replacement frequency by 3050% compared to standard materials, lowering part cost per ton processed

Integrated Magnetic Separator System | Technical Basis: Overbelt selfcleaning electromagnets or drum magnets | Operational Benefit: Automatically extracts liberated ferrous metal during processing without additional handling | ROI Impact: Captures valuable metal scrap directly from the circuit, creating an immediate revenue stream offsetting operational costs.

Centralized Greasing & Hydraulic Systems | Technical Basis: Automated lubrication points and hydraulic adjustment/tramp release systems | Operational Benefit: Ensures critical bearings receive proper lubrication; allows quick clearing of uncrushable objects and remote adjustment of crusher settings | ROI Impact: Minimizes bearing failure risks and reduces downtime for setting changes by over 70%.

PLCBased Control & Monitoring Panel | Technical Basis: Programmable Logic Controller with amp draw monitors and interlock systems | Operational Benefit: Provides operators with realtime equipment status, automates startup sequences, and protects motors from overload | ROI Impact: Enables oneperson operation from a central point and prevents costly motor burnouts.

Modular SkidMounted Design | Technical Basis: Preassembled structural frames for major components | Operational Benefit: Reduces civil foundation work and accelerates onsite installation time significantly | ROI Impact: Cuts installation costs by approximately 25% and allows the plant to become operational weeks faster.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Basic Crushing Circuit) | Our Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability / Uptime | ~7580%, frequent stops for clearing/unjamming| >92%, designed for continuous abrasive duty| +15% throughput time |
| Wear Part Life (Liners/Mantles)| Based on standard manganese steel| Premium workhardening alloys & optimized chamber design| +40% average life |
| Metal Recovery Efficiency| Manual picking postcrushing or basic magnetic separation| Integrated multistage magnetic separation within closed circuit| +95% ferrous capture rate |
| Total Power Consumption| Often oversized motors running inefficiently| Correctly sized motors with PLCcontrolled load management| 10% to 15% energy use per ton |
| Installation & Commissioning Time| 812 weeks for civil works & assembly| 35 weeks with preassembled skids| ~60% faster deployment |

5. TECHNICAL SPECIFICATIONS

Processing Capacity: Configurable from 50 TPH to 300 TPH of raw slag input.
Power Requirements: Total connected load ranges from 150 kW (for 50 TPH plant) to 600 kW (for 300 TPH plant), dependent on configuration. Supply: 415V / 50Hz / 3 Phase (or as per local grid).
Material Specifications: Primary frame constructed from heavyduty structural steel (IS 2062). Chutes & Abrasion Zones lined with replaceable AR400 steel plates (>12mm thickness). Crusher wear parts in premiumgrade Mn18/22 steel.
Physical Dimensions (Typical 150 TPH Plant): Approximate footprint of 35m (L) x 18m (W). Overall height of ~12m including feed hopper.
Environmental Operating Range: Designed for ambient temperatures from 10°C to +45°C. Dust suppression spray systems are fitted at transfer points. Enclosed electrical panels rated IP65.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard | Challenge: Manual breaking of large slag lumps was slow and hazardous; metal recovery was inefficient with significant loss to landfill. Unpredictable feedstock caused daily jams in existing equipment.| Solution: Installation of a turnkey 200 TPH slag crusher plant with heavyduty apron feeder, jaw crusher, cone crusher, dual vibrating screens, and two stages of magnetic separation.| Results: Achieved consistent processing of entire slag output; increased recovered scrap metal yield by over 90%; produced commercially valuable aggregate; eliminated manual breaking labor costs within one year.

Independent Slag Processing Contractor | Challenge: Mobile crushing units suffered rapid wear on highabrasion slag sites; setup/teardown time cut into profitable operating hours; inconsistent final product quality affected sales agreements.| Solution Deployment of a semimobile skidmounted slag crusher plant designed for relocation between mediumterm contracts (624 months). Included quickdisconnect power/feed modules.| Results Reduced relocation time from two weeks to four days; wear part costs decreased by an estimated third due to applicationspecific design; ability to guarantee consistent aggregate gradation secured premium offtake contracts.

7. COMMERCIAL CONSIDERATIONS

Our slag crusher plants are offered in three primary tiers:
1. Standard Configuration: Includes core crushing modules (feeder + primary + secondary/screen), basic magnetic separator(s), starterlevel control panel.
2. Optimized Configuration: Adds automated lubrication systems PLC control panel with monitoring dust suppression system reinforced chute linings
3.
4.Turnkey Premium Configuration Full plant automation advanced metal separation technologies like eddy current separators comprehensive service package including initial spares stock

Optional features include diesel generator modules mobile tracks/wheels specific dust collection units custom conveyor lengths

Service packages range from annual inspection plans comprehensive maintenance contracts guaranteeing parts availability response times Financing options include direct purchase capital lease structures operating lease agreements tailored project financing

8.FAQ

Q What types of slags can your plants process
A Our plants are engineered primarily for ferrous slags blast furnace BOF EAF They can also process certain nonferrous slags but we require sample testing recommend configuration review specific materials like copper nickel

Q How does your design prevent damage from uncrushable metals tramp iron
A Our primary jaw crushers feature hydraulic toggle release systems secondary cone impactors often include hydraulic tramp release automatic reset functions These protect the machinery clearing uncrushables without requiring manual intervention inside chamber

Q What ongoing maintenance should we expect
A Daily greasing visual checks automated via centralized lube system Weekly inspections conveyor belts screen meshes Monthly monitoring wear part thicknesses Major component replacement intervals vary based throughput but typically scheduled annually during planned shutdowns

Q Can we integrate your new plant our existing conveying screening infrastructure
A Yes our engineering team conducts presale audits existing layouts We design interface points ensure compatibility provide necessary modifications drawings ensure smooth integration minimizing disruption current operations

Q What typical delivery timeline after order confirmation
A For Standard Optimized configurations lead time typically 20 weeks exworks Turnkey projects require detailed site survey may extend 32 weeks depending complexity Site installation commissioning supervised our engineers takes approximately 4 weeks

Q Do you provide performance guarantees
A Yes we offer guaranteed minimum throughput capacity based agreed feed specification guaranteed product sizing We also provide extended warranties core crushing components subject proper maintenance protocols