1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with significant hidden costs. Are you facing these operational challenges?
Low Throughput & High Downtime: Inefficient primary crushing creates a backlog, stalling downstream processing and idling material handling crews.
Excessive Abrasion & Maintenance Costs: Standard crushers wear rapidly when processing highly abrasive slag, leading to frequent liner changes, high spare parts consumption, and unpredictable maintenance budgets.
Unreliable Size Reduction: Inconsistent feed size and composition result in poor fragmentation, causing recirculation loads that strain crushers and reduce overall plant efficiency by 1525%.
High Operational Complexity: Equipment requiring constant adjustment and monitoring increases labor intensity and the potential for unplanned stoppages.

The core question for plant managers is this: how can you transform slag from a costly byproduct into a efficiently processed, revenuegenerating aggregate without compromising your primary production line?

2. PRODUCT OVERVIEW

Our HighQuality Slag Crusher Plant is a heavyduty, stationary or semimobile processing system engineered specifically for the rigorous demands of ferrous and nonferrous slag reduction. It is designed to function as the primary size reduction node in your slag valorization circuit.

Operational Workflow:
1. Feed & PreScreening: Runoffurnace slag is fed via dump truck or loader onto a robust grizzly feeder, which removes fine fractions (50mm) to bypass the crusher, increasing effective capacity.
2. Primary Crushing: Oversize material is directed into the core jaw crusher, where its high inertia and optimized kinematics fracture large slabs (up to 1200mm) into manageable pieces.
3. Discharge & Conveying: Crushed material is discharged onto a heavyduty belt conveyor system for transport to secondary screening or stockpiling.

Application Scope: Ideal for integrated steel mills, copper smelters, ferroalloy plants, and standalone slag processing yards handling blast furnace (BFS) or steel slag.
Limitations: Not designed for raw ore primary crushing or processing materials with extreme soil or clay contamination without preprocessing.

3. CORE FEATURES

HeavyDuty Jaw Crusher | Technical Basis: Optimized nip angle and reinforced manganese steel castings | Operational Benefit: Sustained high throughput on abrasive materials with less wearinduced chamber deformation | ROI Impact: Extends liner life by up to 40%, reducing direct spare parts cost and changeout downtime.

Integrated Grizzly Feeder | Technical Basis: Stepped grizzly bars with adjustable spacing | Operational Benefit: Removes fines prior to crushing, preventing chamber packing and maximizing throughput of oversize material | ROI Impact: Increases effective crusher capacity by 2030%, improving total circuit efficiency.

PLCBased Automation System | Technical Basis: Centralized control with load management and fault diagnostics | Operational Benefit: Enables singleoperator oversight, optimizes power draw, and provides early warning for maintenance events | ROI Impact: Reduces labor requirements for operation and minimizes risk of catastrophic failure through proactive monitoring.

Modular Base Frame & Walkways | Technical Basis: Preassembled, bolttogether structural modules | Operational Benefit: Simplifies site installation and foundation work, improves access for safe maintenance | ROI Impact: Cuts installation time by up to 35%, accelerating timetooperation and improving technician safety.

HeavyDuty Discharge Conveyor | Technical Basis: Impactresistant idlers at loading point and chevron belting | Operational Benefit: Handles sharp, heavy crushed slag without belt damage or spillage at transfer points | ROI Impact: Eliminates chronic conveyor maintenance issues, ensuring consistent product flow to stockpile.

Dust Suppression Ready Design| Technical Basis: Preplumbed nozzle mounting points at key dust generation zones | Operational Benefit: Allows easy integration of water spray systems to control particulate emissions during crushing| ROI Impact: Facilitates compliance with environmental standards without costly postinstallation modifications.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average Jaw Plant) | Our Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life (Abrasive Slag)| 60,000 80,000 tonnes| 100,000 110,000 tonnes| +40% |
| Availability (Uptime)| ~85% (incl. liner changes)| ~92% (incl. scheduled maintenance)| +7 percentage points |
| Tons per Hour (Effective)| Subject to fines packing| Consistent via prescreening grizzly| +25% (context dependent) |
| Installation & Commissioning| 45 weeks on site| 23 weeks with modular design| 35% time reduction |
| Specific Power Consumption| Baseline reference kWh/tonne| Field data shows reduction via optimized load control| 8% to 12% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 150 to 600 tonnes per hour (TPH), depending on feed size and required product gradation.
Primary Crusher: Heavyduty jaw crusher model options from 42”x30” up to 60”x48” feed opening.
Power Requirements: Total installed power typically between 200 kW – 450 kW; configured for 400V/50Hz or other industrial standards.
Key Material Specifications: Crusher jaws manufactured from Mn18Cr2 or Mn22Cr2 alloy steel; main frame constructed from ST523 grade steel plate; abrasionresistant liners at all wear points.
Physical Dimensions (Typical Setup): Approximate footprint of 25m (L) x 8m (W) x 7m (H). Semimobile skid versions available.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dustprotected electrical components; optional heating/cooling packages available.

6. APPLICATION SCENARIOS

Integrated Steel Complex – Blast Furnace Slag

Challenge A major steel producer faced daily bottlenecks at its aging slag dump. The existing crusher required biweekly liner checks and produced inconsistent aggregate size, limiting sales of the processed BFS aggregate.
Solution Implementation of a turnkey HighQuality Slag Crusher Plant with integrated grizzly feeder replaced the old system. The PLC automation allowed integration with their central control room.
Results Liner inspection intervals extended to six weeks. Plant availability increased from ~78% to over 90%. The consistent product quality enabled a new contract for railway ballast supply.

Copper Smelter – Slag Processing Yard

Challenge A smelter’s expansion project required onsite processing of granulated copper slag into construction sand. Space was limited,and rapid deployment was critical.
Solution A semimobile configuration of the Slag Crusher Plant was selected,fitted with specific jaw plates for granulated slag.The modular design allowed erection on a prepared pad within two weeks.
Results The plant achieved full design capacity of 250 TPH within three days of commissioning.The compact layout met site constraints,and the produced sand met ASTM C33 specifications for concrete work.

7. COMMERCIAL CONSIDERATIONS

Our HighQuality Slag Crusher Plants are offered in three primary tiers:
1. Standard Configuration: Includes core jaw crusher,vibrating grizzly feeder,basic discharge conveyor,and motor starters.Priced as a capital equipment investment.
2. Optimized Configuration: Adds PLC automation,dust suppression ring main,ladder & walkway packages,and upgraded wear liners.Includes an extended warranty package.Available via capital purchase or leasetoown financing plans.
3. Turnkey Solution: Full engineering,supply,factory testing,civil works guidance,and commissioning supervision.Includes multiyear service agreements covering planned maintenance,inspections,and preferential spare parts supply.Financing options including equipment rental are available.

Optional features include metal detection systems,magnet separators for tramp iron removal,custom conveyor lengths,and sound attenuation enclosures.Service packages range from basic technical support to fullservice maintenance contracts managed by our field engineers.

8.FAQ

Q1 Is this plant compatible with our existing downstream screening and conveying equipment?
A1 Yes.The discharge height,belt width,and speed of the main outfeed conveyor are engineered during quotation phase to match your existing layout.Product sizing can be adjusted through crusher setting changes within its designed range.

Q2 What is the expected operational impact during installation?
A2 For replacement projects,the modular design minimizes disruption.We provide detailed phasing plans.Often,the new plant can be assembled adjacent to the old one,followed by a scheduled tiein outage typically under one week.For greenfield sites,the reduced installation time accelerates project completion.

Q3 How does this solution address abrasive wear compared to standard manganese steel?
A3 We utilize premiumgrade alloyed manganese steels(Mn18Cr2/Mn22Cr2).Industry testing demonstrates these alloys develop a harder workhardened surface under impact,increasing service life in highabrasion applications like slag crushing by approximately 40%.

Q4 What are typical payment terms?
A4 For standard configurations,a deposit upon order confirmation followed by progress payments tied to major manufacturing milestones.Turnkey projects follow an agreed payment schedule based on equipment delivery,system erection,and successful performance testing.Commercial leasing structures are also available upon credit approval.

Q5 Can it handle wet or sticky slag?
A5 The integrated grizzly feeder provides significant benefit here,but extremely wet material can reduce screening efficiency.We recommend evaluating feed moisture content.Crusher design allows handling some moisture,but dedicated predrying may be needed if material adheres consistently.We can advise based on your specific sample analysis

Q6 What training is provided for our operators?
A6 Comprehensive training is included with Optimizedand Turnkey packages.It covers normal operation,troubleshooting via the PLC interface,safety procedures,and basic daily maintenance checks.Documentation includes detailed operationand maintenance manuals in English

Q7 What defines 'highquality' in this context beyond durability?
A7 It encompasses three pillars engineered reliability ensuring predictable uptime intelligent design features like prescreening that optimize total process flow not just machine outputand build quality using traceable materials that meet stated specifications providing longterm structural integrity