1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
Unplanned Downtime: Frequent breakdowns of underengineered crushers halt downstream processing, costing thousands per hour in lost production and labor.
Excessive Wear & Maintenance Costs: The abrasive, unpredictable nature of slag rapidly degrades standard components, leading to unsustainable parts replacement cycles and maintenance labor expenses.
Inconsistent Output & Product Quality: Poor crushing yields uneven particle size distribution, compromising the value of your final aggregate product and causing issues in subsequent material handling or sales.
Regulatory & Environmental Risk: Noncompliant equipment can lead to site violations, while dust and debris from inefficient processing create unsafe working conditions and potential liability.

The core question is: how do you transform this problematic byproduct into a consistent, profitable product line without sacrificing reliability or compliance? The answer requires a purposebuilt system designed for the task.

2. PRODUCT OVERVIEW

A RoHS Compliant Slag Crusher Plant is a stationary or semimobile processing system engineered specifically to reduce slag from metallurgical processes (blast furnace, steel furnace) into specified aggregate sizes. It is constructed with materials and components that adhere to the Restriction of Hazardous Substances (RoHS) directive, ensuring no controlled substances are present in the machinery itself—a critical factor for operations with strict environmental procurement policies or those selling aggregate into regulated markets.

Operational Workflow:
1. Primary Crushing: Dumpfed slag is reduced by a robust primary jaw crusher capable of handling large, irregular feed.
2. PreScreening & Separation: A vibrating grizzly or scalper removes fine material and debris prior to secondary crushing, improving overall efficiency.
3. Secondary Crushing: A cone crusher or impact crusher further reduces the material to the target product size.
4. Final Screening & Stockpiling: Crushed material is classified via vibrating screens into commercial fractions (e.g., 05mm, 520mm) and conveyed to designated stockpiles.

Application Scope: Ideal for integrated steel plants, standalone slag processing yards, and aggregate producers specializing in industrial byproducts. Best suited for ferrous slags with moderate to high abrasiveness.

Limitations: Not designed for primary rock mining of virgin stone or for processing nonabrasive materials where a simpler system would suffice. Maximum feed size and hardness are defined by the primary crusher model selected.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: Reinforced manganese steel jaws & oversized bearings | Operational Benefit: Sustained throughput with infrequent wear part changes, handles large slablike slag pieces | ROI Impact: Reduces primary station downtime by up to 30% annually versus standard crushers

RoHSCompliant Construction | Technical Basis: Documentationbacked supply chain for motors, wiring, hydraulics, and coatings | Operational Benefit: Eliminates risk of noncompliant materials contaminating your process chain or final product | ROI Impact: Protects market access for your aggregates and avoids costly procurement audits or remediation

Integrated Dust Suppression System | Technical Basis: Strategically placed spray nozzles with solenoid control tied to crusher operation | Operational Benefit: Maintains visible dust levels well below OSHA thresholds, creating a safer environment | ROI Impact: Minimizes housekeeping labor and reduces wear on plant components caused by abrasive dust

Centralized Greasing & Monitoring | Technical Basis: Automated lubrication points for key bearings with lowlevel alerts | Operational Benefit: Extends bearing life in highcontamination environments; provides operators with clear system health status | ROI Impact: Prevents catastrophic bearing failures, reducing unscheduled maintenance events

Modular Discharge Conveying | Technical Basis: Customizable radial conveyors or fixed stackers for segregated product stockpiling | Operational Benefit: Enables precise sorting of multiple product grades simultaneously without rehandling | ROI Impact: Increases saleable product yield by minimizing crosscontamination of size fractions

AbrasionResistant Linings | Technical Basis: AR400 steel plate liners in hoppers, chutes, and skirts at critical wear points | Operational Benefit: Dramatically extends service life in highimpact zones between crusher stages | ROI Impact: Lowers annual liner replacement costs and associated installation labor

PLCBased Control Panel | Technical Basis: Simple automated sequencing with fault diagnostics displayed locally | Operational Benefit: Allows for quick startup/shutdown sequences and faster troubleshooting by your electrical team | ROI Impact: Reduces operator error and shortens mean time to repair (MTTR)

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | RoHS Compliant Slag Crusher Plant Solution | Advantage (% improvement) |
|||||
| Wear Part Life (Primary Jaw) | 6090 days in severe slag duty | 120150 days with optimized metallurgy | Up to 67% longer |
| System Uptime Availability | ~8085% due to reactive maintenance | Target of 9295% with predictive features | ~12% increase |
| Dust Emission Control | Passive measures (skirts, occasional water) | Active suppression system integrated at source >60% reduction in airborne particulates |
| Energy Consumption per Ton Varies widely; often inefficient motor/crusher pairing Crusher & conveyor motors sized for optimal load Documented 815% reduction based on load analysis |
| Compliance Documentation Often limited; generic component certificates Full material declarations for major assemblies 100% traceability for regulated substances |

5. TECHNICAL SPECIFICATIONS

Processing Capacity: Configurable from 50 TPH to over 300 TPH.
Feed Size: Accepts slag up to 800mm edge length (model dependent).
Power Requirements: Primary plant motor load typically ranges from 150 kW to 400 kW; total connected load includes conveyors and auxiliaries. Designed for 400V/50Hz or other industrial standards.
Material Specifications: Primary frame construction from heavyduty S355 steel; critical wear areas lined with AR400/AR500 abrasionresistant steel; all electrical components from RoHScompliant manufacturers.
Physical Dimensions (Typical Setup): Footprint approximately 25m L x 15m W x 12m H (varies significantly with configuration).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system rated effective up to wind speeds of level 5.

6. APPLICATION SCENARIOS

Integrated Steel Mill – Slag Yard Modernization

Challenge A major steel producer faced escalating disposal costs for granulated blast furnace slag and frequent breakdowns of aging mobile crushers causing production delays at their melt shop.
Solution Implementation of a turnkey RoHS Compliant Slag Crusher Plant with integrated scalping screen located at the slag dump site.
Results Achieved consistent production of 020mm aggregate at >180 TPH. Plant availability reached 94%, eliminating melt shop delays related to slag handling. The produced aggregate now generates a new revenue stream instead of incurring disposal fees.

Independent Aggregate Producer – Niche Market Expansion

Challenge An aggregate supplier sought entry into the industrial slag processing market but required guarantees their endproduct would meet strict environmental standards demanded by their readymix concrete clients.
Solution A midcapacity RoHS Compliant Slag Crusher Plant was selected specifically for its documented component compliance alongside high abrasion resistance.
Results The producer secured longterm contracts with two concrete batching plants requiring certified clean aggregates. The plant’s low wear rate resulted in operating costs comparable to processing natural granite.

7. COMMERCIAL CONSIDERATIONS

Pricing tiers are structured around throughput capacity and automation level:
Base Configuration (50100 TPH): Includes primary jaw crusher, basic discharge conveyor, starterlevel control panel.
Standard Configuration (100200 TPH): Most common package featuring primary jaw + secondary cone/impact crusher integrated screening module PLC control automated lubrication
HighCapacity/Turnkey Configuration (200+ TPH): Includes all standard features plus comprehensive dust suppression advanced diagnostics telemetry capability extended walkways/service platforms

Optional Features:
Metal detector/magnet separator
Additional screening decks
Finished product washing module
Sound attenuation enclosures
Service Packages:
Annual maintenance contracts provide scheduled inspections parts discounts priority technical support Financing Options Flexible arrangements including leasing capital equipment loans can be discussed based on project scope facilitating CAPEX planning

8. FAQ

Q1 Is the entire plant truly RoHS compliant including all subcomponents?
A1 Yes Our systems are supplied with full material declaration dossiers Major assemblies motors switchgear wiring hydraulic hoses etc are sourced from manufacturers who certify RoHS compliance providing you auditable documentation

Q2 Can this plant integrate with our existing material handling equipment?
A2 Absolutely Feed hoppers discharge heights conveyor speeds control interfaces can be engineered during design phase match your current yard layout transfer points ensuring smooth integration

Q3 What is typical installation timeline once equipment arrives on site?
A3 For a semi modular plant foundation preparation precedes delivery Mechanical erection electrical connection commissioning typically require weeks depending complexity Site civil works conducted concurrently minimize total project timeline

Q4 How does wear part pricing compare standard rock crushing equipment?
A4 While initial cost specialized liners jaws may higher their extended service life lower cost per ton processed Field data shows total annual expenditure wear parts often lower due reduced change out frequency labor savings

Q5 What training provided our operations maintenance teams?
A5 Comprehensive training included covering safe normal operation routine maintenance checks troubleshooting procedures We provide detailed manuals conduct onsite sessions during commissioning ensure your team confident managing system