1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with significant hidden costs. Are you facing these common operational challenges?

Low Throughput & High Downtime: Inefficient primary crushing and frequent clogging from wet or sticky slag create production halts, delaying downstream processes and shipment schedules.
Excessive Wear & Maintenance Costs: The abrasive nature of slag rapidly degrades standard crusher components, leading to unpredictable maintenance cycles, high parts replacement costs, and strained operational budgets.
Inconsistent Final Product Quality: Poorly sized output with excessive fines or oversized chunks complicates material handling, reduces the market value of your processed slag aggregate, and can cause issues in subsequent processing or sales.
High Operational Labor & Energy Costs: Equipment requiring constant operator intervention for clearing or adjustment, coupled with inefficient power consumption per ton crushed, directly erodes profit margins.

Is your current setup equipped to transform this challenging byproduct into a consistent, profitable product stream? A purposeengineered professional slag crusher plant is the systematic answer.

2. PRODUCT OVERVIEW

A professional slag crusher plant is a stationary or semimobile crushing circuit specifically engineered to reduce metallurgical slag (blast furnace, steel furnace, etc.) from large furnace chunks to a precisely graded aggregate. Its design prioritizes durability, continuous operation, and product control to handle this uniquely abrasive and variable material.

Operational Workflow:
1. Primary Receiving & PreScreening: Feed material is received via dump truck or loader onto a grizzly feeder to scalp off fine material and direct oversize to the primary crusher.
2. Primary Size Reduction: A heavyduty jaw crusher or impact breaker performs the initial crushing, reducing large slag blocks to a manageable size (typically <200mm).
3. Secondary Crushing & Shaping: A secondary cone crusher or impact crusher further processes the material, focusing on cubical product shaping and precise size reduction.
4. Final Screening & Classification: Vibrating screens separate the crushed slag into specified product fractions (e.g., 05mm, 520mm, 2040mm). Oversize material is recirculated.
5. Stockpiling & Dispatch: Graded aggregates are conveyed to designated stockpiles for loading out or for further processing.

Application Scope: Ideal for integrated steel plants, standalone slag processing yards, and aggregate producers specializing in industrial byproducts. Effective on aircooled blast furnace slag (BFS) and basic oxygen furnace/steelmaking slags.

Limitations: Not designed for molten slag handling. Performance against extremely highdensity or tramp metalcontaminated feedstock requires specific prescreening and protection systems.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: Reinforced manganese steel jaws/liners with optimized nip angle | Operational Benefit: Sustained high throughput on large, hard slab slag with minimal risk of bridging or stall | ROI Impact: Reduces primary stage downtime by up to 30%, ensuring continuous feed to downstream circuits

AbrasionResistant Material Flow System | Technical Basis: Hardox® liners in hoppers and chutes; ceramic lagging on critical pulley points | Operational Benefit: Dramatically extends service life in highwear zones, containing abrasive dust | ROI Impact: Lowers annual liner replacement costs by an average of 40% compared to standard carbon steel systems

Hydraulic Adjustment & Clearing | Technical Basis: Integrated hydraulic cylinders for crusher gap setting and tramp metal release | Operational Benefit: Allows operators to adjust product size or clear a chamber blockage in minutes without manual disassembly | ROI Impact: Cuts nonplanned maintenance time by over 50%, protecting revenue during peak operation

Centralized Greasing & Condition Monitoring | Technical Basis: Automated lubrication system with points at all major bearings; ports for vibration and temperature sensors | Operational Benefit: Ensures optimal bearing health, provides early warning of potential failures | ROI Impact: Extends major bearing service intervals by ~25% and prevents catastrophic drive system failures

HighCapacity Vibrating Screens with Deck Options | Technical Basis: Robust screen box with interchangeable wire mesh or polyurethane deck panels | Operational Benefit: Provides reliable classification in highabrasion conditions; panels can be swapped for different product specifications | ROI Impact: Improves screening efficiency to >95%, maximizing saleable product yield and reducing recirculation load

PLCBased Control & Monitoring Panel | Technical Basis: Programmable Logic Controller managing startup sequence, interlocking,and process monitoring | Operational Benefit: Enables smooth plant rampup/down from a single location; provides operational data log for efficiency analysis | ROI Impact: Optimizes power draw per ton crushed and reduces personnel required for routine plant operation

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Professional Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | ~8285% (downtime for wear part changes/blockages)| ~9295% (design for quick maintenance/clearing)| +1012% |
| Liner Life Primary Stage| Standard Manganese Steel (~40k MT)||
||
||
|
|
|
|
|
|
|
|

5. TECHNICAL SPECIFICATIONS

Processing Capacity: Configurable from 50 to over 400 tons per hour.
Feed Size Maximum: Up to 1000mm (slag blocks direct from pit).
Final Product Range: Adjustable from 03mm sand up to 4080mm aggregate.
Power Requirement: Total installed power typically ranges from 150kW to 450kW depending on plant configuration.
Key Material Specifications: Primary crusher jaws/liners in Mn18Cr2 alloy steel; conveyor chute liners in Hardox® 400/500; screen decks in replaceable hightensile wire mesh or PU.
Physical Footprint (Typical Setup): Approximately 35m (L) x 22m (W) x 15m (H). Semimobile configurations available.
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature; dust suppression system compliant with local particulate emission standards.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Recycling Challenge:

Unpredictable downtime of aging equipment caused piling of raw slag,
delaying site operations and creating storage headaches.Solution:
Installation of a turnkey professional slag crusher plant with heavyduty apron feeder
and hydraulic jaw crusher as the primary unit.Results: Achieved consistent throughput
of180TPH,increased aggregate production by35%,and cleared backlog within8weeks,
enabling regular site logistics.

Independent Aggregate Producer Challenge:

An aggregate supplier soughtto diversify into industrial byproducts but found their
existing limestone crushing circuit suffered excessive wearand poor shape when processing purchased BFS.Solution:
Deploymentofadditionalsecondaryslagspecificcone crusher moduleand upgraded
abrasionresistant conveyors integrated into existing flow.Results: Successfully producedhighvalue cubical BFS aggregate meeting road base specifications;
wear part lifecycle on the new module increasedby2.5x comparedtothe existing plant handlingthe same material.

7.COMMERCIAL CONSIDERATIONS

Pricing forturnkeyprofessional slagcrusher plants scaleswith capacityand complexity.Entrylevel configurationsfor~80TPHstartfrom amidrange capital investment.Comprehensive systemsfor250+TPHrepresent apremium investmentwith correspondingly higher returns.

Optional featuresinclude metal detectors/magnetic separators,dust collection systems,
automated sampler systems,and portabletrackmounted primary unitsfor multipit operations.

Service packagesare recommendedand typically include scheduled preventive maintenance inspections,wears pare kitsheldin consignment stock,and priority technical support.Financing options including equipment leasingand term loansare commonly availableto spreadthe capital outlay againstthe revenue generatedbythe plant's output.

8.FAQ

Q:What if ourslagfeed contains occasional large tramp metal?
A:Theplant designcan incorporate suspended plate magnets over feed conveyorsand tramp metal detection systems with automatic conveyor stoppage.Hydraulic clearing cylinders inthe primarycrusheraddressany metal that enters the chamber.

Q:What isthe expected power consumption per ton crushed?
A:Efficiency varieswith feed hardnessand desired reduction ratio.Field datafrom similar installations shows arangeof0.8to1.4kWh per tonfor typical steel slags,a1525%improvementover retrofitted generalpurpose plants due todrive system optimization.

Q:Canyourplant connectto our existing screeningand conveying infrastructure?
A:Yes.Engineering assessmentsfocuson interoperability.Plant controlscan be adaptedto interfacewith your wider system,and conveyors can be specifiedtomatch existing heightsand discharge points.

Q:What arethe lead timesfor deliveryand commissioning?
A:Fors tandard designs,fabrication lead time averages1620weeksfrom order.Site foundation preparation bythe client proceedsin parallel.Onsite mechanical erectionandelectrical commissioningby our technicians typically requires34weeksdependingon plantsize.

Q:What trainingis providedfor our operations team?
A:A comprehensive handover includes classroom trainingonthe PLC control system,lubrication schedules,and safety procedures,followedby several daysof supervised handson operation during production commissioning.We provide detailed operationand maintenance manuals.

Q:Arethere financing solutions available?
A Yes we workwith several industrial equipment finance partners tooffer lease purchase agreementsor installment plans makingthe capital expenditure more manageable Payments can often be structuredto alignwith your projected cash flowfrom increasedaggregate sales