Slag Crusher Plant Vendor Datasheet
Slag Crusher Plant Vendor Datasheet: Engineering Reference for Procurement and Installation
1. Le défi opérationnel: Why Standard Crushing Equipment Fails in Slag Processing
Chaque 10,000 tons of steel production generates approximately 1,500–2,000 tons of slag. Your plant's profitability depends on how efficiently you convert this byproduct into reusable aggregates, metal recovery feedstock, or cementgrade material. Encore, plant managers consistently face the same bottlenecks:
- Premature wear and tear: Standard jaw and cone crushers experience 40–60% faster component degradation when processing slag due to its abrasive mineralogy (containing free lime, magnesia, and metallic iron particles). Replacement of wear liners on a conventional crusher processing slag can cost $18,000–$45,000 per cycle, with downtime of 3–5 days per changeout.
- Metal contamination damage: Tramp metal (scrap steel, rebar fragments) entering the crushing chamber causes catastrophic structural failure. Industry data indicates unplanned downtime from metalrelated damage averages 12–18 hours per incident, costing $8,000–$15,000 per hour in lost production.
- Moisture and temperature variability: Slag feed material can arrive at 200–400°C from the cooling pit, with moisture content fluctuating between 3% et 12%. Standard crushers experience packing, colmatage, and thermal stress under these conditions.
- Classement incohérent des produits: Meeting strict specifications for road base (0–40mm), agrégat d'asphalte (0–14mm), or cement feed (0–5mm) requires precise control that conventional singlestage crushing cannot deliver.
The question is not whether you need slag processing equipment—it is whether your current vendor understands the specific metallurgical, thermique, and abrasive demands of slag. This datasheet provides the engineering baseline for evaluating a dedicated slag crusher plant solution.
2. Présentation du produit: The Dedicated Slag Crusher Plant System
A slag crusher plant is an integrated, multistage processing system engineered specifically for the reduction of ferrous and nonferrous slag into saleable aggregates and recoverable metallic fractions. Unlike retrofit solutions, this dedicated plant addresses the unique physical properties of slag: high abrasivity (Mohs hardness 6–7), elevated temperature at feed point, and the presence of ductile metallic contaminants.
Flux de travail opérationnel (5Stage Process)
1. Trémie d'alimentation & Alimentateur vibrant: Accepts slag from dump trucks or conveyor discharge. The heavyduty grizzly feeder (with 50–75mm gap) scalps oversized material and removes fines, while the hopper liner is fabricated from 20mm Hardox 450 to resist impact abrasion.
2. Concasseur à mâchoires primaire (SlagSpecific Configuration): A reinforced jaw crusher with a 1.5x safety factor on the toggle plate mechanism. The crushing chamber is designed with a wider feed opening (typically 900×750mm) to accept slag chunks up to 600mm. The eccentric shaft is forged from 40CrNiMoA alloy steel, and the fixed jaw plate uses a waveshaped profile to improve interparticle crushing of brittle slag.
3. Séparation magnétique (Primaire & Secondaire): Overband magnetic separators (suspension type, 1200mm belt width) remove ferrous metals after primary crushing. This step is critical—it recovers 90–95% of the metallic iron content (worth $250–$350 per ton as scrap) and protects downstream crushers from damage.
4. Concasseur à cône secondaire (Robuste): A springrelease cone crusher with a special crushing cavity (grossier, moyen, or fine) matched to the target product size. The main shaft is supported by a largediameter spherical bearing to absorb shock loads from residual metal. Hydraulic adjustment allows closedside setting (CSS) changes from 25mm down to 6mm without stopping the plant.
5. Tamis vibrant & Product Conveyors: Un écran incliné à trois étages (par ex., 2YK2460) classifies material into 0–5mm, 5–15mm, 15–25mm, and 25–40mm fractions. Each product stream is conveyed to dedicated stockpiles or directly to downstream processes (alimentation du broyeur à boulets, centrale à béton, etc.).
Portée et limites de l'application
| Applicable Feed Materials | Limites |
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| Laitier de haut fourneau (aircooled, granulated) | Not suitable for wet slag with >15% moisture without predrying |
| Steelmaking slag (BOF, AEP, LF) | Feed temperature must be below 80°C for standard belt conveyors |
| Ferroalloy slag (FeCr, FeMn, FeSi) | Taille maximale du flux: 600mm (larger requires primary breaking) |
| Copper/nickel smelter slag | Not designed for radioactive or hazardous waste materials |
| Incinerator bottom ash (IBA) | Throughput reduces by 30–40% when processing highclaycontent feed |
3. Fonctionnalités principales: Engineering Specifications and Operational Benefits
Reinforced Welded Frame Construction | Base technique: Analyse par éléments finis (FEA)répartition optimisée des contraintes | Avantage opérationnel: Frame deflection reduced to <0.5mm à pleine charge, ensuring bearing alignment and extended component life | Impact sur le retour sur investissement: 15–20% longer service life compared to standard fabricated frames, réduire la fréquence de remplacement du capital
The main crusher frame is fabricated from Q345B lowalloy steel plates (20–30mm thickness), stress soulagé après le soudage. FEA analysis confirms that stress concentrations at the bearing housing and toggle seat areas are maintained below 80 MPa—well within the material's fatigue limit. This design prevents the frame cracking commonly observed in modified standard crushers used for slag.
SlagSpecific Manganese Steel Wear Parts | Base technique: Highworkhardening austenitic manganese steel (Mn13Cr2 or Mn18Cr2) | Avantage opérationnel: Wear life of 4,000–6,000 hours on jaw plates and 3,000–4,500 hours on cone liners when processing typical blast furnace slag | Impact sur le retour sur investissement: Replacement wear parts cost $12,000–$28,000 per set; extended life reduces annual wear part expenditure by 25–35%
Standard Mn18Cr2 (18% manganèse, 2% chrome) is specified for the primary jaw. For the secondary cone crusher, we recommend Mn13Cr2 with a thicker crosssection (up to 120mm at the feed point) to withstand the impact of residual metal. The wear parts are cast using the Vmethod (vacuum sealed) processus, ensuring uniform hardness of 170–220 HB in the ascast condition, workhardening to 450–550 HB on the working surface.
Système de libération de tramp hydraulique | Base technique: Accumulatorcharged hydraulic cylinders with 40mm stroke | Avantage opérationnel: Passes uncrushable metal (up to 150mm diameter) through the chamber in 3–5 seconds, automatically resetting to the original CSS | Impact sur le retour sur investissement: Élimine 90% of unplanned downtime events; typical payback period of 6–9 months based on avoided repair costs
The hydraulic system operates at 120–160 bar and is equipped with a nitrogen accumulator that absorbs the shock of metal entry. Sensors monitor cylinder position; if the CSS does not return to setpoint within 10 secondes, the system triggers an alarm and stops the feed belt, preventing secondary damage.
DualStage Magnetic Separation with Metal Recovery Conveyor | Base technique: Neodymium (NdFeB) permanent magnets with 12,000 Gauss surface field strength | Avantage opérationnel: Récupère 95% of ferrous metals >10mm from the slag stream; recovered metal is conveyed to a dedicated bunker | Impact sur le retour sur investissement: Metal recovery revenue of $8–$15 per ton of slag processed (at current scrap prices), representing 10–15% of total plant revenue
The primary overband magnet is positioned at a 45degree angle over the main discharge conveyor, while the secondary magnetic head pulley (at the screen feed conveyor) captures residual fines. The metal recovery rate is verified through periodic sampling: données de terrain de 12 installations shows average recovery of 38–52 kg of metal per ton of BOF slag.
Dust Suppression and Sealing System | Base technique: Multistage water spray nozzles (atomized, 50–100 micron droplets) at transfer points and crusher inlets | Avantage opérationnel: Airborne dust concentration at the plant boundary maintained below 2 mg/m³ (meets EU and US EPA standards) | Impact sur le retour sur investissement: Avoids regulatory fines of $10,000–$50,000 per violation; improves operator working conditions, reducing staff turnover
The system includes a highpressure pump (70 bar), a ring main around the crusher house, and ultrasonic sensors that activate sprays only when material flow is detected—reducing water consumption to 0.5–1.0 m³ per hour. For coldclimate installations, an optional airatomizing system (using compressed air instead of water) est disponible.
PLCBased Automated Control with Remote Monitoring | Base technique: Automate Siemens S71200 avec écran tactile IHM (10pouce) and optional SCADA integration | Avantage opérationnel: Singleoperator supervision of the entire plant; automatic start/stop sequencing; realtime display of motor currents, températures des roulements, et niveaux de vibrations | Impact sur le retour sur investissement: Labor cost reduction of 2–3 operators per shift; predictive maintenance alerts reduce repair costs by 20–25%
The control system monitors 32 analog inputs (ampères moteur, température, pression) et 48 digital inputs (limit switches, proximity sensors). Alarm thresholds are configurable; the system logs all events with timestamps for ISO 9001 compliance audits.
Conception modulaire montée sur patins | Base technique: ISO containercompatible modules (20ft and 40ft footprint) | Avantage opérationnel: Plant relocation achievable in 5–7 days using standard flatbed trailers; foundation work reduced to simple concrete pads | Impact sur le retour sur investissement: Relocation costs of $15,000–$25,000 versus $80,000–$120,000 for a fixed plant; enables contract crushing at multiple sites
Each module (unité de concassage, unité d'écran, système de convoyeur) is prewired and prepiped at the factory. Site installation requires only: (1) concrete pad preparation (2–3 jours), (2) module placement and alignment (1–2 jours), (3) electrical connection to the site transformer (1 jour), et (4) commissioning and test run (2 jours).
4. Avantages compétitifs: Comparaison des performances
| Mesure de performances | Norme de l'industrie (Modified Aggregate Crusher) | Solution dédiée à l'usine de concassage de scories | Avantage (% Amélioration) |
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| Durée de vie des pièces d'usure (plaques à mâchoires) | 1,800–2,500 hours | 4,000–6 000 heures | 60–140% longer |
| Temps d'arrêt imprévus (metalrelated) | 12–18 hours/month | 2–4 hours/month | 75–85% reduction |
| Taux de récupération des métaux | 60–70% (single magnet, no dedicated recovery) | 90–95% (dualstage with recovery conveyor) | 30–40% higher recovery |
| Cohérence de la gradation des produits (P90 within spec) | 75–80% of production runs | 95–98% of production runs | 20–25% improvement |
| Throughput efficiency (tons/hour per kW) | 0.8–1.2 t/h/kW | 1.5–2.0 t/h/kW | 25–65% higher efficiency |
| Temps de changement (remplacement de pièce d'usure) | 16–24 heures (grue + travail manuel) | 8–12 heures (hydraulic tools + guided alignment) | 50% plus rapide |
| Coût d'entretien annuel (comme % de la valeur de l'équipement) | 8–12% | 5–7% | 35–45% lower |
| Niveau d'émission de poussière (plant boundary) | 5–10 mg/m³ (often noncompliant) | <2 mg/m³ (conforme) | 60–80% de moins |
Data compiled from field studies of 15 slag processing installations (2019–2024) and manufacturer test reports.
5. Spécifications techniques: Configuration standard (Model SCP200)
Capacity and Performance Ratings
| Paramètre | Valeur | Remarques |
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| Rated throughput | 150–200 t/h | Based on feed density of 1.6–2.0 t/m³, feed size ≤600mm |
| Taille maximale du flux | 600mm (longueur du bord) | Larger requires primary breaking or grizzly modification |
| Gamme de tailles de produits | 0–5mm, 5–15mm, 15–25mm, 25–40mm | Adjustable via screen mesh selection and crusher CSS |
| Rapport de réduction (primaire) | 4:1 à 6:1 | Jaw crusher CSS: 75–150mm |
| Rapport de réduction (secondaire) | 3:1 à 5:1 | Cone crusher CSS: 6–25mm |
| Metal recovery capacity | 15–30 t/h of ferrous scrap | Based on 10–15% metal content in feed |
Exigences d'alimentation
| Component | Puissance installée (kW) | Operating Power (kW) | Voltage/Frequency |
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| Concasseur à mâchoires primaire (PE750×1060) | 110 | 75–95 | 380V/50Hz ou 460V/60Hz |
| Concasseur à cône secondaire (PYB1750) | 160 | 110–140 | 380V/50Hz ou 460V/60Hz |
| Tamis vibrant (2YK2460) | 30 | 22–26 | 380V/50Hz ou 460V/60Hz |
| Séparateurs magnétiques (2 unités) | 7.5 chaque | 5.5 chaque | 380V/50Hz ou 460V/60Hz |
| Convoyeurs (6 unités, total length 85m) | 45 (total) | 30–38 | 380V/50Hz ou 460V/60Hz |
| Dust suppression pump | 11 | 7.5 | 380V/50Hz ou 460V/60Hz |
| Puissance totale installée | ~370 kW | ~250–320 kW | — |
Spécifications matérielles
| Component | Matériel | Hardness/Strength | Remarques |
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| Plaques à mâchoires (fixé & mobile) | Mn18Cr2 austenitic manganese steel | 170–220 HB (ascast), workhardens to 450–550 HB | Reversible design for extended life |
| Doublures de cône (manteau & concave) | Mn13Cr2 with 120mm max thickness | 170–220 HB (ascast) | Thicker at feed zone |
| Cadre & main structure | Q345B lowalloy steel, 20–30mm plate | Yield strength: 345 MPa | Stressrelieved after welding |
| Trémie & doublures de goulotte | Hardox 450 (ou équivalent) | 425–475 HB | 20mm épaisseur, bolton replaceable |
| Arbres (excentrique & main) | 40Acier allié CrNiMoA | 280–320 HB (traité thermiquement) | Forgé, then precision machined |
| Roulements (broyeur) | Roulements à rotule sur rouleaux (SKF/FAG) | C4 clearance | Greaselubricated, automatic lubrication optional |
Physical Dimensions and Weight
| Module | Longueur (m) | Largeur (m) | Hauteur (m) | Poids (tonnes) |
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| Feed hopper + grizzly feeder | 6.5 | 3.2 | 3.8 | 12.5 |
| Primary jaw crusher module | 5.8 | 3.5 | 4.2 | 28.0 |
| Secondary cone crusher module | 5.2 | 3.8 | 5.5 | 32.5 |
| Screen module (triple pont) | 7.0 | 3.0 | 4.5 | 15.0 |
| Système de convoyeur (total) | 85 (linéaire) | 1.2 (largeur de la ceinture) | — | 18.5 |
| Empreinte totale de l'usine | ~45m × 25m | — | — | ~110 tons (équipement uniquement) |
Plage de fonctionnement environnementale
| Paramètre | Plage de fonctionnement | Remarques |
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| Température ambiante | 20°C à +50°C | Forfait temps froid en option (radiateurs, lubrifiants spéciaux) en dessous de 10°C |
| Température du matériau d'alimentation | ≤80°C at crusher inlet | Higher temperatures require cooling conveyor or water spray |
| Humidité relative | 5–95% (sans condensation) | Electrical enclosures rated IP54 minimum |
| Altitude | Up to 2,000m above sea level | Derating of 1% per 100m above 1,000m for motor power |
| Niveau de bruit (at 1m from equipment) | ≤85 dB(UN) | Meets EU Machinery Directive 2006/42/EC |