1. PAINPOINT DRIVEN OPENING

Managing slag is a critical but costly bottleneck. Are you facing these persistent operational challenges?
Unplanned Downtime: Frequent breakdowns of underengineered crushers halt your entire processing line, costing thousands per hour in lost throughput and labor.
Excessive Wear & Maintenance Costs: The abrasive nature of slag rapidly degrades standard crusher components, leading to unsustainable spending on replacement parts and maintenance labor.
Inconsistent Product Gradation: Poor crushing yields unevenly sized material, compromising the quality and market value of your final aggregate product.
High Operational Costs: Inefficient power consumption and low throughput per ton directly erode your profit margins on every processing cycle.
Compliance & Safety Risks: Equipment not built for heavyduty mineral processing can pose safety hazards and fail to meet stringent site or environmental regulations.

What if your slag processing plant could achieve predictable output, lower costperton, and operate with greater reliability? The solution requires equipment engineered specifically for this demanding task.

2. PRODUCT OVERVIEW

The ISO Certified Slag Crusher Plant is a stationary or semimobile crushing circuit designed explicitly for the primary, secondary, and tertiary reduction of iron, steel, and ferroalloy slag. Engineered by a private label manufacturer with deep expertise in mineral processing, it transforms bulky slag feed into valuable, specificationgrade aggregate.

Operational Workflow:
1. Primary Crushing: Large slag feed (up to 1000mm) is reduced by a robust jaw crusher or impactor.
2. PreScreening & Secondary Crushing: Material is screened; oversize is routed to a cone crusher for further reduction.
3. Final Screening & Stockpiling: Crushed material is classified into precise product fractions (e.g., 05mm, 520mm) via vibrating screens and conveyed to stockpiles.

Application Scope: Ideal for integrated steel plants, standalone slag processing yards, and aggregate producers handling blast furnace (BFS) or steel furnace slag.

Limitations: Not designed for virgin rock mining/quarrying primary applications or for processing materials with high moisture content without preprocessing.

3. CORE FEATURES

HeavyDuty Rotor & Chamber Design | Technical Basis: Finite Element Analysis (FEA) optimized stress distribution | Operational Benefit: Withstands continuous impact from dense, abrasive slag with minimal deformation | ROI Impact: Extends major component service life by up to 40%, reducing capital replacement cycles

Liner & Wear Part Metallurgy | Technical Basis: Highchrome white iron alloys and manganese steel formulations | Operational Benefit: Provides exceptional resistance to abrasive wear specific to slag composition | ROI Impact: Lowers costperton for wear parts by an average of 30% compared to standard crushers

Intelligent Drive & Power Management | Technical Basis: Hydrostatic or direct drive systems with PLCcontrolled variable frequency drives (VFDs) | Operational Benefit: Optimizes power draw based on load, prevents jamming, and allows soft starts | ROI Impact: Reduces energy consumption by 1525% and eliminates downstream damage from stall events

Integrated Tramp Metal Protection | Technical Basis: Hydraulic or pneumatic release systems coupled with reinforced construction | Operational Benefit: Automatically discharges uncrushable metals that commonly exist within slag feed | ROI Impact: Prevents catastrophic damage to crusher internals, avoiding repair costs exceeding tens of thousands per incident

Modular Plant Configuration | Technical Basis: Bolttogether skid or module design with standardized interfaces | Operational Benefit: Enables rapid site installation, reconfiguration, or future plant expansion with minimal civil work | ROI Impact: Cuts installation time and costs by up to 50% compared to welded foundationbased plants

Centralized Greasing & Monitoring System | Technical Basis: Automated lubrication system with flow sensors and centralized control point | Operational Benefit: Ensures critical bearings receive correct lubrication without manual intervention in highdust environments | ROI Impact: Eliminates bearing failure due to undergreasing, a leading cause of unplanned downtime

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical Crusher) | ISO Certified Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability / Uptime | 8085% (high downtime for wear changes) |> 92% (scheduled maintenance only) |> 8% Improvement |
| Wear Part Life (Liners)| Based on granite/limestone; severely reduced in slag| Alloyspecified for slag abrasion| Up to 40% Longer Life |
| Power Consumption per Ton| Fixed speed drives; inefficient under partial load| VFDoptimized load management| 1525% Reduction |
| Finished Product Cubicity| Variable; often flaky due to improper compression| Consistent, cubical aggregate from optimized cavity| Improved yield in premium grades |
| Installation / Commissioning Time| 46 weeks for fixed foundation plant| 1015 days for modular skid plant| ~60% Faster Deployment |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to over 400 TPH final product.
Feed Size: Accepts runofslag up to 1000mm edge length.
Power Requirements: Plantwide requirement from 150 kW to 600 kW depending on configuration; supplied at either standard industrial voltages.
Key Material Specifications:
Crusher Main Frame: Fabricated from heavyduty steel plate (min. yield strength >355 MPa).
Wear Liners / Jaw Plates / Concaves / Blow Bars: Premiumgrade manganese steel (Mn18Cr2/Mn22Cr2) or High Chrome Iron (Cr26/28).
Screen Decks / Conveyor Skirting : Abrasionresistant steel liners.
Physical Dimensions (Example MidRange Plant): Approx. Length: 25m x Width: 8m x Height: 6m
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dustsealed electrical components; IP65 rating on critical motors and controls.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Recycling

Challenge A major steel producer faced escalating landfill costs for BFS slag and needed consistent aggregate quality for internal road construction but suffered from high crusher maintenance costs.
Solution Implementation of a turnkey ISO Certified Slag Crusher Plant configured as a twostage closed circuit system tailored specifically for their BFS chemistry.
Results Achieved consistent production of 20mm aggregate at >95 TPH availability. Reduced external aggregate purchase by $180k annually while cutting internal wear part costs by an estimated $50k/year versus their previous setup.

Independent Aggregate Producer Processing EAF Slag

Challenge An aggregate contractor securing Electric Arc Furnace (EAF) slag contracts experienced poor product yield due to uncrushable tramp metal causing weekly breakdowns in their generalpurpose cone crusher.
Solution A primary jaw crusher plant equipped with enhanced tramp metal release was installed as the dedicated first stage ahead of their existing circuit.
Results Tramp metal incidents causing downtime were reduced by over . The jaw's robust design increased primary throughput by , allowing the overall plant to meet new contract volumes reliably.

7. COMMERCIAL CONSIDERATIONS

Our private label manufacturing model provides flexibility across commercial needs:

Pricing Tiers: Solutions range from core equipment supply only up through full turnkey project delivery including civil works supervision.
Optional Features & Upgrades: Consider magnetic separation modules integrated into conveyors , dust suppression systems , automated sampling systems , or extended remote monitoring packages .
Service Packages: Choose from basic commissioning support up through comprehensive annual maintenance contracts including guaranteed spare parts availability .
Financing Options: We work with established partners offering equipment leasing structures .

8. FAQ

1. Q Is this ISO Certified Slag Crusher Plant compatible with our existing conveyors screens?
A Yes provided interface specifications are shared during design Our standard designs use common industry transfer heights belt widths We provide detailed interface drawings .

2 Q What is the expected operational impact during installation?
A For modular skid plants site impact is minimal requiring only leveling cranes Electrical connection typically causes the longest lead time We provide detailed site preparation guidelines .

3 Q How does the private label model benefit us as a buyer?
A It removes brand premiums associated with major OEMs while delivering equivalent performance You invest directly in engineered specifications not marketing overhead This typically results in cost savings .

4 Q What are typical payment terms?
A Standard commercial terms involve progress payments tied key milestones such as order confirmation completion fabrication ready shipment successful commissioning These are detailed proposal .

5 Q Can you guarantee specific wear part life metrics?
A We provide databacked performance projections based your specific analysis However final wear life depends actual material characteristics feed rate We guarantee metallurgical specification parts supplied meet exceed stated standards .

6 Q What training do you provide our operators maintenance staff?
A Comprehensive training conducted during commissioning covers safe operation routine maintenance troubleshooting procedures All documentation including manuals parts lists provided digital hard copy formats .

7 Q Who handles aftersales service technical support?
A Direct access our engineering support team via dedicated channels We maintain critical spare parts inventory ensure rapid response times support requests .