1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent, costly bottleneck. Are you facing these operational challenges?
Unplanned Downtime: Frequent clogging and abrasive wear in standard crushers lead to unscheduled maintenance stops, halting your entire material flow.
High Operational Costs: Excessive power consumption from inefficient crushing cycles and the recurring expense of replacing worn manganese steel components directly erode profit margins.
Inconsistent Output: Variable feed size and hardness result in an unpredictable product grade, complicating downstream processing or sales to aggregate markets.
Space & Labor Constraints: Multistage, fragmented crushing setups require significant footprint and constant operator oversight for feeding and monitoring.
Dust & Noise Compliance: Meeting increasingly stringent site environmental and safety regulations with open or inadequately controlled systems adds complexity and risk.

Is there a slag processing solution engineered to directly address these reliability, cost, and output quality issues?

2. PRODUCT OVERVIEW

The Luxury Slag Crusher Plant is a hightonnage, integrated processing system designed for the primary and secondary reduction of blast furnace (BF) slag, steel slag, and ferroalloy slag. It transforms large, irregular slag feed into precisely graded aggregate for cement substitution, road base, or rail ballast.

Operational Workflow:
1. Primary Reduction: Feed material (up to 1000mm) is introduced into a heavyduty jaw crusher or impact crusher for initial size reduction.
2. PreScreening & Bypass: A preliminary scalping screen removes fines prior to secondary crushing, increasing overall plant efficiency.
3. Secondary Crushing & Shaping: The core hydraulic cone crusher performs interparticle crushing for optimal cubical product shaping and final size reduction.
4. Final Sizing & Separation: A multideck vibrating screen classifies output into 24 specified product fractions (e.g., 05mm, 510mm, 1020mm).
5. Dust Suppression Integration: A closedloop spray system manages dust at all transfer points, ensuring compliance.

Application Scope & Limitations:
Scope: Ideal for stationary or semimobile plants processing 150 2000 TPH of metallurgical slag. Effective for both ferrous and nonferrous slags with moderate to high abrasiveness.
Limitations: Not designed for primary rock mining applications with extremely high compressive strength (>350 MPa). Feed must be prescreened to remove excessive metallic content (tramp metal) to protect crusher internals.

3. CORE FEATURES

Intelligent Hydraulic CSS Adjustment | Technical Basis: PLCcontrolled hydraulic setting regulation | Operational Benefit: Operators can adjust the crusher's closedside setting (CSS) onthefly for different product grades without stopping the plant. | ROI Impact: Reduces product changeover time by up to 80%, maximizing utilization and enabling rapid response to market demand.

Liner Wear Compensation System | Technical Basis: Automated hydraulic positioning that maintains CSS as wear components degrade | Operational Benefit: Consistent product gradation is maintained throughout the liner lifecycle without manual intervention. | ROI Impact: Eliminates periodic yield loss due to drift in CSS, ensuring up to 15% more consistent premiumgrade output.

Hybrid Dust Control System | Technical Basis: Highpressure micromist nozzles combined with strategic sealing at transfer points | Operational Benefit: Effectively suppresses airborne particulate without oversaturating material, which can cause handling issues. | ROI Impact: Mitigates regulatory noncompliance risks and reduces housekeeping labor by an estimated 30%.

HeavyDuty Rotor & Bearing Assembly | Technical Basis: Forged alloy steel rotor with oversized spherical roller bearings in a labyrinth seal arrangement | Operational Benefit: Sustains high inertia for efficient crushing of slablike slag pieces with exceptional reliability. | ROI Impact: Extends major service intervals by 23x compared to standard assemblies, lowering costperton significantly.

Centralized Greasing & Monitoring | Technical Basis: Automated singlepoint lubricator with feedback sensors connected to the plant SCADA | Operational Benefit: Ensures optimal bearing lubrication under all load conditions and provides early warning of potential faults. | ROI Impact: Prevents catastrophic bearing failures, which are a leading cause of extended unplanned downtime.

Modular Discharge Conveyor System | Technical Basis: Radial slewable stacker or fixed conveyors with variable speed drives | Operational Benefit: Enables precise stockpiling of multiple product fractions without requiring additional mobile equipment. | ROI Impact: Reduces material rehandling costs and minimizes loader fuel consumption and operator hours.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Luxury Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life (Abrasive Slag)| Manganese Steel Jaw Liners (~60k tons)| Advanced Composite Jaw/Cone Liners| +4060% Extended Life |
| Power Consumption per Ton| Fixed Speed Drives on all motors| Variable Frequency Drives (VFDs) on feeders & conveyors| 18% Energy Usage |
| Product Shape Index (Cubicity)| Standard Cone Crusher Output| Interparticle Crushing in Hydraulic Cone| +25% Improved Cubicity |
| Mean Time Between Failure (MTBF)| ~450 operating hours| ~1200 operating hours| +167% Reliability |
| Total Footprint Requirement| MultiStage Separate Units| Single Integrated Plant Design| 35% Space Needed |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 150 TPH to 1,200 TPH nominal throughput on BF slag (Bulk Density ~1.6 t/m³).
Power Requirements: Total connected load from 350 kW to 900 kW depending on configuration; primary crusher motor typically 160400 kW.
Material Specifications: Crusher frames constructed from welded steel plate (minimum S355J2). Highwear components utilize multialloy castings or ceramic composites.
Physical Dimensions (Typical Setup): Length (~35m) x Width (~12m) x Height (~9m). Designed for flat concrete foundation or modular skid mounting.
Environmental Operating Range: Fully operable from 20°C to +45°C ambient temperature with optional heating/cooling packages for lubrication systems. IP65 rating on electrical panels.

6. APPLICATION SCENARIOS

Integrated Steel Mill – Slag Aggregate Production

Challenge: A major mill’s legacy hammer mill system suffered from weekly breakdowns, producing flaky aggregate unsuitable for highvalue concrete applications, resulting in significant revenue loss.
Solution: Implementation of a turnkey Luxury Slag Crusher Plant featuring a primary impactor and secondary cone crusher with precise shaping controls.
Results: Plant availability increased from 94%. The consistent, cubical aggregate now commands a 22% price premium in the readymix concrete market. Payback was achieved in under 18 months through reduced maintenance costs and increased sales revenue.

Independent Slag Processing Contractor – Mobile Deployment

Challenge: A contractor needed to process stockpiled slag at multiple remote sites but could not justify the capital for several fixed plants. Existing mobile units lacked the throughput and dust control for largescale contracts.
Solution: Deployment of a semimobile Luxury Slag Crusher Plant on modular skids, complete with integrated dust suppression and power pack.
Results: The plant was relocated between three sites within one year. Its consistent 400 TPH output and complianceready operation allowed the contractor to secure longterm tollprocessing agreements based on guaranteed performance metrics.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers:
Standard Configuration: Includes primary jaw crusher, secondary cone crusher, basic screening, and conveyor system.
Enhanced Configuration: Adds hydraulic setting adjustment, advanced dust control system, VFDs on key components,
and full PLC automation with SCADA interface.
Premium Configuration: Fully customized system including metal detection/removal,
automated liner wear monitoring,
and remote diagnostic telematics.

Optional Features: Tramp metal detection systems,
acoustic enclosures,
winterization packages,
different screen media types (polyurethane,
piano wire),
extended discharge conveyors.

Service Packages
Proactive Maintenance Plan: Scheduled inspections,
predictive analytics based on operational data,
and guaranteed spare parts availability.
FullService Contract: Includes all labor,
parts,
and planned component replacements (e.g.,
liners,
bearings) for a fixed costperton processed.

Financing Options: Capital lease agreements,
operating leases,
and project financing solutions are available through accredited partners to match your cash flow requirements.

8\. FAQ

Q1:
Is this plant compatible with our existing feed system
and downstream material handling?
A:
Our engineering team conducts a full review of your interface points
(feed hopper height/discharge conveyor specs)
. The plant is designed with adaptable connections
to integrate into most existing layouts.

Q2:
What is the expected operational impact during installation
and commissioning?
A:
For a greenfield site,
we manage turnkey installation
. For retrofit scenarios,
we develop a phased implementation plan minimizing disruption
, typically requiring a scheduled shutdown of 710 daysfor mechanical tieins
.

Q3:
How does the equipment pricing structure work?
A:
Pricing is projectspecific based on required capacity
and configuration. We provide firm lumpsum quotations covering equipment supply ,
commissioning ,
and initial operator training.

Q4:
What kind of operator training is provided?
A:
We offer comprehensive onsite training covering normal operation ,
troubleshooting ,
safety procedures ,
and basic preventive maintenance for your operations
and maintenance teams.

Q5:
What is the typical lead time from order placement
to delivery?
A:
Lead times vary by complexity .
For standard configurations ,
expect 1624 weeks.
We provide detailed project schedules upon inquiry .

Q6:
Can you guarantee final product specifications?
A:
Yes .
Based on your feed material analysis ,
we will provide performance guarantees for throughput capacity ,
product gradation curves ,

power consumption per ton.

Q7:
Are spare parts readily available?
A:
We maintain strategic global inventories of critical wear
and mechanical parts.
Our service network can typically dispatch priority parts within 2448 hours.