1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
Unplanned Downtime: Frequent clogging and abrasive wear in standard crushers lead to unscheduled maintenance, halting downstream processes and costing thousands per hour in lost production.
High Operating Costs: Excessive energy consumption from inefficient crushing cycles, combined with the high cost of replacing worn manganese steel components, erodes your profit margins.
Inconsistent Output: Variable feed size and composition result in an uneven product, complicitating material handling and reducing the value of your processed slag for resale or further use.
Space & Logistics Constraints: Bulky, multistage crushing setups require significant plant footprint and complex material transfer systems, increasing capital expenditure and operational complexity.

What if your slag processing could be more predictable, costcontained, and efficient? The solution lies in equipment engineered specifically for the task.

2. PRODUCT OVERVIEW

The OEM Slag Crusher Plant is a heavyduty, integrated processing system designed for the primary and secondary reduction of metallurgical slag (blast furnace, steel furnace). It transforms large, irregular slag feed into a controlled, sized aggregate for use in construction, road base, or cement additives.

Operational Workflow:
1. Feed & PreScreening: Runoffurnace slag is fed via hopper; an integrated grizzly or scalper removes fine fractions to bypass the crusher, increasing throughput.
2. Primary Crushing: A robust jaw crusher or impact breaker performs initial size reduction, handling large lumps with high compressive strength.
3. Material Transfer & Secondary Crushing: A network of heavyduty conveyors moves material to a secondary cone or impact crusher for final sizing.
4. Sizing & Stockpiling: Crushed material passes over vibrating screens to separate into specified grades (e.g., 40mm, 20mm) before being conveyed to stockpiles.

Application Scope & Limitations:
Scope: Ideal for integrated steel plants, smelters, and standalone slag processing yards handling ferrous slags. Effective for producing specification aggregates.
Limitations: Not designed for wet, sticky materials without predrying. Maximum input lump size is defined by the primary crusher opening (typically up to 8001000mm). Extremely hightramp metal content requires additional protection systems.

3. CORE FEATURES

HeavyDuty Rotor & Impact Elements | Technical Basis: Highinertia rotor design with replaceable blow bars | Operational Benefit: Sustains high crushing force on abrasive slag; allows for quick bar rotation/replacement to maintain product gradation | ROI Impact: Reduces wear part changeout downtime by up to 30% versus standard designs.

Hydraulic Adjustment & Clearing | Technical Basis: Integrated hydraulic cylinders for crusher gap setting and tramp metal release | Operational Benefit: Enables precise product size control onthefly and protects the crusher from uncrushables without manual intervention | ROI Impact: Minimizes risk of major damage events; field data shows a 65% reduction in stallrelated downtime.

AbrasionResistant Liner Package | Technical Basis: Bolton liners made from proprietary AR400/500 steel in highwear zones (hopper, feed chute, impact chambers) | Operational Benefit: Dramatically extends service life in critical wear areas; simplifies replacement | ROI Impact: Lowers liner consumable costs by an average of 40% over the plant's lifecycle.

Integrated Scalping & Bypass System | Technical Basis: Precrusher vibrating grizzly feeder with fines discharge conveyor | Operational Benefit: Removes subsize material prior to crushing chamber, increasing effective throughput and reducing unnecessary wear on crusher components | ROI Impact: Improves overall system capacity by 1525%, optimizing energy use per ton processed.

Centralized Greasing & Monitoring Points | Technical Basis: Manifolded lubrication lines for all major bearings with accessible service points | Operational Benefit: Enables safe, rapid routine maintenance from ground level or service platforms; reduces lubrication time by half | ROI Impact: Lowers planned maintenance labor hours and improves bearing life through consistent lubrication.

Modular SkidMounted Design | Technical Basis: Preassembled crusher, feeder, and conveyor modules on structural skids | Operational Benefit: Reduces civil works and installation time; simplifies relocation if operational needs change | ROI Impact Cuts installation costs and timetooperation by approximately 30% compared to traditional foundationbased builds.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Generic Crusher Plant) | OEM Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Tons per Hour / kW (Energy Efficiency) | 80100 tph per 250kW installed power| 110130 tph per 250kW installed power| +2530% More Efficient |
| Wear Part Life (Blow Bars/Hammers) | 15,000 20,000 tons throughput| 25,000 35,000 tons throughput| +67% Longer Life |
| Mean Time Between Failure (MTBF)| ~450 operating hours| ~720 operating hours| +60% Improved Reliability |
| Installation & Commissioning Time| 812 weeks postdelivery| 57 weeks postdelivery| ~40% Faster Deployment |
| Product Gradation Consistency (±5mm spec)| Requires frequent manual adjustment| Maintained via hydraulic adjustment; minimal drift| Up to 50% less variation |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 to over 400 metric tons per hour.
Power Requirements: Primary drive motors from 110kW to 375kW; total plant connected load dependent on configuration.
Material Specifications: Fabricated from S355JR structural steel; highwear components in AR400/500 steel; crusher rotors in forged alloy steel.
Physical Dimensions (Example Model SCP200): Length ~25m x Width ~8m x Height ~6m (excluding feed hopper). Skidmounted modular design.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression system ready (water spray nozzles standard). Enclosed motors and IP65rated electrical panels standard.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Recycling

Challenge A major Asian steel producer faced escalating landfill costs for blast furnace slag and needed a reliable onsite solution to create saleable aggregate. Their existing equipment suffered from constant jamming and excessive wear.
Solution Implementation of a turnkey OEM Slag Crusher Plant with a heavyduty impact crusher as the core component and integrated magnetic separation postcrushing.
Results The plant achieved a consistent output of 25mm aggregate at 180 tph. Landfill costs were eliminated within 14 months. Wear part lifecycle increased by over twice compared to their previous setup.

Independent Construction Aggregate Producer

Challenge A European processor sought highervalue products but struggled with inconsistent feed material from various demolition sources containing metallic contaminants that damaged their conventional jaw crushers.
Solution Deployment of an OEM Slag Crusher Plant configured with a deepcleaning overhead magnet on the feed conveyor and a primary jaw crusher equipped with automatic hydraulic clearing.
Results Uncrushable tramp metal events were managed automatically without shutdowns. Product consistency improved yield within specification by over twenty percent yearonyear

Ferroalloy Smelter Byproduct Processing

Challenge A smelter’s existing hammer mill system required excessive maintenance downtime when processing highly abrasive ferrochrome slag creating production bottlenecks
Solution Replacement with an OEM Slag Crusher Plant built around a high inertia horizontal shaft impactor featuring quickchange wear parts
Results Throughput increased by thirty percent while annual maintenance hours decreased by two hundred The resulting consistent granulate became a certified product line

7 COMMERCIAL CONSIDERATIONS

Pricing tiers are structured around capacity throughput:
Tier I (250 tph): Custom engineered systems often including tertiary crushing stages

Optional Features:
Advanced PLC automation package with remote monitoring capability
Dust extraction baghouse system beyond standard water spray
Hot slag handling modifications including special conveyor belts
Extended wear part packages including rotors mantles etc

Service Packages:
Standard warranty covering parts labor one year comprehensive support available
Preventive maintenance contracts including scheduled inspections parts discounts emergency call out priority
Operator training programs conducted onsite during commissioning

Financing Options:
Capital lease operating lease structures available through our financial partners tailored payment schedules can be aligned with project cash flow milestones

FAQ Section

Q1 Is this plant compatible with our existing material handling equipment feeders stackers etc?
A1 Yes The OEM Slag Crusher Plant is designed with standardized discharge heights belt widths control voltage interfaces allowing integration into most existing layouts Our engineering team conducts pre order reviews to confirm compatibility

Q2 What is the expected operational impact on our current workforce?
A2 Your operators will benefit from simplified controls centralized service points reduced manual clearing tasks Comprehensive training ensures your team can manage routine operations maintenance confidently within two weeks of commissioning

Q3 How does this solution address variable feed sizes common in slag yards?
A3 The combination of a vibrating grizzly feeder optional hydraulic adjustment allows the system handle significant variation Industry testing demonstrates consistent product grading even with ± thirty percent variation in input lump sizes

Q4 What are typical commercial terms delivery lead times?
A4 Standard lead times range between sixteen twenty four weeks ex works depending model complexity Payment terms typically involve progress payments against milestones like design approval shop fabrication completion shipment Commercial leasing options are also available detailed upon request

Q5 What site preparation is required before installation?
A5 Site requires level compacted ground capable supporting point loads detailed foundation drawings provided Our modular skid design minimizes civil work primarily requiring simple concrete pads anchor bolts Utility connections power water dust suppression lines must be stubbed within ten meters main electrical panel