1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Inefficient processing directly impacts your bottom line through equipment wear, lost material value, and operational delays. Are you facing these challenges?
High Downtime for Jaw Replacement: Frequent clogging and abrasive wear in primary crushers lead to excessive maintenance stops, costing hundreds of production hours annually.
Inefficient Material Recovery: Poor size reduction yields inconsistent slag aggregate, limiting its marketability for construction or causing reprocessing costs.
Unplanned Maintenance Costs: The unpredictable failure of components not designed for slag's abrasive and sometimes corrosive nature results in high spare part inventories and emergency repair bills.
Low System Throughput: A mismatched or underperforming crushing circuit becomes the choke point for your entire metal recovery or aggregate production line.
Dust and Noise Compliance: Open crushing operations generate significant fugitive dust and noise, creating environmental compliance risks and unsafe working conditions.

The central question for plant managers is this: how can you transform slag from a costly byproduct into a reliable revenue stream while controlling operational expenses?

2. PRODUCT OVERVIEW

A highquality slag crusher plant is a purposeengineered, stationary or semimobile processing system designed to reduce large chunks of blast furnace, steel, or nonferrous slag into precisely graded aggregate. It integrates robust primary and secondary crushing with screening and material handling for a complete turnkey solution.

Operational Workflow:
1. Feed & PreScreening: Runoffurnace slag is fed via loader or conveyor. A heavyduty grizzly or scalping screen removes fine material (30mm) bypassing the crusher, increasing efficiency.
2. Primary Size Reduction: A rugged jaw crusher or impact breaker handles the initial crushing, reducing large slabs (up to 1000mm) to manageable sizes (150200mm).
3. Secondary Crushing & Shaping: A secondary cone crusher or impact crusher further reduces the material, producing a wellshaped, cubical aggregate product (2050mm).
4. Final Screening & Stockpiling: Vibrating screens classify the crushed output into multiple product fractions (e.g., 05mm, 520mm, 2040mm) which are conveyed to separate stockpiles.

Application Scope: Ideal for integrated steel plants, smelters, scrap yards, and independent aggregate producers handling ferrous (blast furnace, BOF) and nonferrous slags.
Key Limitation: Not designed for primary ore processing or extremely hard igneous rock. Feed material should be free of uncrushable tramp metal beyond specified limits; magnetic separators are recommended upstream.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: Modified kinematics & premium manganese steel jaws | Operational Benefit: Handles slabby feed without clogging; jaw life increased by up to 40% over standard designs | ROI Impact: Reduces replacement part costs and downtime by an estimated 18% annually

Adaptive Crushing Chamber | Technical Basis: Hydropneumatic overload protection & hydraulic adjustment | Operational Benefit: Automatically relieves tramp metal events; allows remote CSS adjustment for different product grades without stopping | ROI Impact: Prevents catastrophic damage; enables quick product changeovers boosting plant flexibility

Integrated Dust Suppression System | Technical Basis: Nozzle arrays at transfer points with solenoid control | Operational Benefit: Reduces airborne particulate by over 95% at source during crushing operations | ROI Impact: Mitigates health/safety risks and ensures continuous compliance with environmental regulations

Centralized Greasing & Monitoring | Technical Basis: Automated lubricant delivery to all major bearings with flow sensors | Operational Benefit: Ensures optimal bearing lubrication regardless of operator shift changes; provides early failure warnings | ROI Impact: Extends bearing service life by an average of 30%, preventing unplanned stoppages

Modular Plant Design | Technical Basis: Bolttogether subassemblies on heavyduty support frames | Operational Benefit: Reduces civil foundation costs and enables future reconfiguration or relocation of the plant | ROI Impact: Lowers initial installation cost by approximately 15% and protects longterm asset value

HighEfficiency Vibrating Screens | Technical Basis: Multideck screens with replaceable modular polyurethane panels | Operational Benefit: Provides precise sizing with high throughput; panel changes are faster than replacing entire wire decks | ROI Impact: Improves product quality consistency and reduces screen maintenance time by half

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | HighQuality Slag Crusher Plant Solution | Advantage (% improvement) |
| : | : | : | : |
| Availability / Uptime | ~8285% (including planned maintenance)| >92% demonstrated availability| +810% more productive hours |
| Wear Cost per Tonne| $0.85 $1.10 USD/tonne| $0.55 $0.70 USD/tonne| ~30% reduction in consumables cost |
| Product Yield (inspec aggregate)| Typically 7580% of feed mass| Consistently achieves 8588% yield| +710% more saleable product |
| Power Consumption per Tonne| Baseline (100%) reference| Optimized drive systems reduce consumption to ~90% of baseline| ~10% energy savings |
| Installation & Commissioning Time| 812 weeks for fixed foundation plants| Modular design reduces time to 46 weeks| ~50% faster timetooperation |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 tonnes per hour (TPH) to over 400 TPH.
Feed Size Maximum: Up to 1000mm x 800mm slab form.
Final Product Sizes: Adjustable from coarse railway ballast (4080mm) down to fine aggregate (05mm).
Power Requirements: Total installed plant power from 150 kW to 600 kW depending on configuration; standard supply at 400V/50Hz or customized.
Key Material Specifications:
Crusher jaws/liners: Manganese steel (14%18%), optional chrome iron for highly abrasive slag.
Mainframe construction: ST52 steel plate with reinforced stress points.
Screen decks: Hardox on support frames with polyurethane or rubber panels.
Physical Dimensions (Typical Medium Plant): Approx. Length: 25m x Width: 8m x Height: 7m
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system effective up to relative humidity of 80%.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Slag Processing

Challenge: A major mill needed to process wetgranulated BF slag into a consistent 6mm product for cement substitution but faced constant clogging in their existing hammer mill circuit, causing weekly downtime.
Solution: Implementation of a highquality slag crusher plant featuring a primary impact crusher with special alloy hammers and an integrated drying/drying chamber within a closedcircuit system with a vibrating screen.
Results: Clogging was eliminated entirely within six months after commissioning while achieving consistent fineness modulus control (+/0). The result was an increase in annual saleable slag powder volume by 22%.

Copper Smelter – NonFerrous Slag Aggregate Production

Challenge: A smelter sought to monetize its stockpiled copper slag as construction aggregate but could not meet local abrasion resistance (Los Angeles) specifications due to poor particle shape from their old jawonly setup while also controlling dust emissions strictly regulated near residential areas nearby
Solution Installation included our modular twostage configuration consisting primarily one deep chamber jaw followed closely behind one cone type secondary unit equipped fully enclosed conveyors plus integrated spray mist suppression throughout all transfer points
Results Final crushed materials tested well below required LA values thus qualifying them premium road base material Additionally airborne particulates measured at property boundary fell significantly under permitted limits allowing uninterrupted operation

Independent Recycling Facility – Processing Diverse Slag Streams

Challenge This facility receives varying types including EAF stainless steelmaking ladle slags which differ widely both hardness chemistry Their previous single machine often produced inconsistent gradation leading customer rejections recrushing costs were high
Solution They selected flexible design allowing quick switch between different liner profiles secondary chamber settings plus added optional metal detector prior primary feed entrance protect downstream equipment against occasional tramp aluminum pieces missed during magnetic separation stage earlier process flow line arrangement used here too maximize recovery rates each batch processed accordingly based its known characteristics beforehand testing lab analysis provided clients themselves before even starting up new runs scheduled accordingly calendar year round basis now possible thanks these advanced features included standard package offered us them originally when first discussed project details together initially meeting held last spring season earlier this timeframe mentioned above already passed since then obviously but point remains same regardless timing factors involved overall success story shared today still relevant nonetheless moving forward future projects alike similar nature scope size scale etcetera...