1. PAINPOINT DRIVEN OPENING

Is your slag handling operation a persistent bottleneck and a source of hidden costs? For plant managers and engineering contractors, the challenges of processing metallurgical slag are multifaceted. Are you experiencing:
Excessive Downtime: Frequent clogging, bridging, and abrasive wear in primary crushing stages halting your entire material recovery line?
Unpredictable Throughput: Inconsistent feed size and composition from ladles leading to capacity fluctuations and missed processing targets?
High Operational Costs: Premature failure of crusher components not designed for extreme abrasion, coupled with high energy consumption per ton processed?
Recovery Inefficiency: Inadequate liberation of metallic fractions from the slag matrix, leaving valuable material in your waste stream and reducing overall plant revenue?
Safety & Maintenance Burdens: Laborintensive clearing of jams and the risks associated with manual handling of large, irregular slag pieces?

These issues directly impact your bottom line through lost production, increased maintenance labor, and suboptimal metal recovery. The core question is: how do you achieve reliable, highvolume slag reduction with predictable operating costs?

2. PRODUCT OVERVIEW: SLAG CRUSHER PLANT

A Slag Crusher Plant is a purposebuilt, stationary or semimobile processing system engineered for the primary, secondary, and sometimes tertiary reduction of aircooled or granulated metallurgical slag. Its function is to liberate entrapped metal (ferrous and nonferrous) from the slag matrix and produce a consistently sized aggregate for sale or further processing.

Operational Workflow:
1. Feed & PreScreening: Runoffurnace slag is fed via loader or conveyor into a robust grizzly or scalping screen to remove fine material (30mm) bypassing the primary crusher.
2. Primary Crushing: Oversize material (+30mm to +500mm) enters a heavyduty jaw crusher or impact breaker designed to handle extreme shock loads and abrasion.
3. Metal Separation & Secondary Crushing: The crushed product is conveyed past an overhead magnetic separator to extract liberated ferrous metal. Remaining material may pass through a secondary cone or impact crusher for final sizing.
4. Final Sizing & Stockpiling: Material is screened into specified aggregate fractions (e.g., 05mm, 510mm, 1020mm) via vibrating screens and conveyed to stockpiles.

Application Scope & Limitations:
Scope: Ideal for integrated steel plants, copper smelters, ferroalloy producers, and standalone slag processing yards handling blast furnace (BF), basic oxygen furnace (BOF), electric arc furnace (EAF), ladle, and nonferrous slags.
Limitations: Not designed for primary rock mining applications. Performance on extremely sticky or highmoisture slags may require predrying or specialized feed systems.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: High Manganese Steel Jaws & Reinforced Frame | Operational Benefit: Sustained performance under extreme shock loads from large, irregular slag pieces with minimal deformation | ROI Impact: Reduces unplanned crusher downtime by up to 40% and extends jaw life by over 60% compared to standard designs.

Integrated Magnetic Separation Circuit | Technical Basis: Overband SelfCleaning Electromagnets positioned at optimal discharge points | Operational Benefit: Continuous, automated recovery of liberated ferrous metal directly from the crushed stream without manual intervention | ROI Impact: Increases metal recovery rates by 1525%, creating a direct revenue stream from what was previously waste.

AbrasionResistant Material Flow System | Technical Basis: AR400/500 steel liners in hoppers, chutes, and skirts; impact beds on conveyor load zones | Operational Benefit: Dramatically reduces wearrelated failures in highimpact areas, maintaining consistent flow geometry | ROI Impact: Lowers annual liner replacement costs by an average of 35% and reduces conveyor belt damage.

Centralized PLC Automation & Monitoring | Technical Basis: Programmable Logic Controller with HMI touchscreen for system control; motor current sensors and bearing temperature monitors | Operational Benefit: Enables oneoperator control of the entire plant with realtime alerts for abnormal conditions like overloads or blockages | ROI Impact: Optimizes power consumption per ton by up to 20% through controlled sequencing; reduces required operational manpower.

Modular SkidMounted Design (Optional) | Technical Basis: Preassembled crusher modules on heavyduty structural skids with integrated walkways | Operational Benefit: Significantly reduces civil works requirements and onsite installation time by up to 70% | ROI Impact: Faster commissioning accelerates timetorevenue; facilitates future relocation if site requirements change.

Dedicated Slag Crusher Plant Dust Suppression System | Technical Basis: Nozzle arrays at transfer points connected to a highpressure pump unit with moisture sensors | Operational Benefit: Effectively controls fugitive dust at source without overwetting material which can cause downstream handling issues | ROI Impact: Ensures compliance with site environmental standards; protects other machinery from abrasive dust ingress.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | This Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability / Uptime| ~7580%, frequent jamming/clogging incidents| >92%, engineered feed system & crushing chamber design| +15% operational availability|
| Wear Cost per Ton Processed| High variability; frequent liner/impeller changes| Predictable cost; extendedlife components documented| 35% average reduction|
| Metal Recovery Efficiency (%)| Manual picking postcrushing or singlestage magnetic separation| Multistage liberation with optimized magnetic separation points| +20% ferrous recovery yield|
| Energy Consumption (kWh/Ton)| Often overlooked; oversized motors running constantly| PLCcontrolled optimized start/stop sequences & VFDs on feeders| 18% average reduction|
| Installation / Commissioning Time| Extensive field fabrication & alignment (1216 weeks)| Pretested modular skids requiring connection only (68 weeks)| 50% site construction time|

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to over 300 TPH of processed slag.
Primary Crusher Options: Jaw Crusher (900 x 600mm to 1500 x 1200mm) or Primary Impact Crusher with hydraulic adjustment.
Power Requirements: Total connected load typically between 250 kW – 800 kW depending on configuration; supplied for 415V/3Phase/50Hz or as specified.
Key Material Specifications:
Crusher Jaws/Hammers/Blow Bars: Premium Manganese Steel (1822% Mn).
Liners/Chutes/Wear Plates: Minimum AR400 Steel.
Structural Frames & Skids: HeavyDuty Pentaplate / IS2062 E350 Grade Steel.
Conveyor Belting: Minimum EP630/4 rated for abrasion resistance.
Physical Dimensions (Typical Modular Plant): Length ~40m x Width ~12m x Height ~9m (excluding feed hopper).
Environmental Operating Range: Designed for ambient temperatures from 10°C to +45°C; dust suppression system maintains operation within PM10 emission standards.

6. APPLICATION SCENARIOS

Integrated Steel Plant – BOF Slag Processing

Challenge: A major steel producer faced severe bridging in their existing crusher feed hopper when processing large BOF slag lumps (>800mm), causing daily downtime. Metal recovery was inefficient using a single magnet after crushing.
Solution: Implementation of a custom Slag Crusher Plant featuring a vibrating grizzly feeder with stepped grizzly bars to break bridges ahead of a deepchambered jaw crusher. Two overband magnets were installed—one precrusher for loose metallics and one postprimarycrusher.
Results: Bridging incidents eliminated entirely. Plant availability increased from 78% to >94%. Ferrous metal recovery improved by 22%, paying back the system’s capital cost in under two years through recovered metal value alone.

Independent Slag Processing Contractor

Challenge: A contractor servicing multiple smalltomedium EAF mills needed a portable solution that could be relocated between sites every 1824 months but required consistent high throughput without lengthy setup times.
Solution: A fully skidmounted Slag Crusher Plant was supplied on four modular sections (feed module with scalper, primary crusher module, screening/magnet module). All modules featured quickdisconnect electrical/pneumatic connections.
Results: Relocation time between sites reduced from three months to four weeks due to minimal civil work required at new locations. Consistent throughput of ~120 TPH maintained across different site configurations.

7. COMMERCIAL CONSIDERATIONS

Our Slag Crusher Plants are offered in three primary tiers based on capacity and automation level:

1. Standard Duty Plant (<100 TPH): Focuses on core reliability with essential features like primary crushing and magnetic separation—ideal for smaller operations prioritizing capital efficiency.
2. HeavyDuty Plant (100 – .200 TPH):) Our most common configuration includes full abrasion protection package advanced PLC automation multistage sizing/screening—designed for maximum total costofownership savings in continuous operation
3.
4.HighCapacity/Turnkey System (>200 TPH):) Includes all heavyduty features plus optional secondary crushing stage automated sampler complete dust collection baghouse system project management services

Optional Features include:
Automated grease lubrication systems
Thermal camera monitoring for bearings
Advanced aggregate cubicity shaping kit
Onboard diesel generator power pack

Service Packages range from basic commissioning/spare parts supply upto comprehensive annual maintenance contracts including scheduled wear part replacement

Financing options including equipment leasing rentalpurchase agreements are available subjecttoqualification providing flexibilityincapitalexpenditureplanning

8.FAQ:

Q1 How do I determine if my specific typeofslag requiresajawcrushersoranimpactcrushersastheprimaryunitintheslagcrushersplants?
A1 The choice dependsonslag characteristics Jaw crushers are generally preferredforhighlyabrasive dense slagswithcompressivestrengthlikeaircooledBFslag duetotheirdirectforceandslowerspeed minimizing wear Impactors can offer higher reduction ratiosandbetter particle shapeforlessabrasive slags like someEAFslag We analyze your samplematerialin our labtoprovideadatabacked recommendation

Q2 Whatisthetypicalinstallationfootprintandfoundationrequirementsforaskidmountedslagcrushersplants?
A2 While significantly reduced comparedtotraditional plants level compacted groundoraminimalconcretethicknesspadissufficientforskid placement Major civil workislimitedtofeedhopperpitsandfinalproducttunnelconveyors if applicable Detailed foundation drawings are providedforsitepreparation

Q3 CananexistingslagcrushersplantsbeupgradedwithyourkeyfeaturesliketheenhancedmagneticcircuitorPLCautomations?
A3 Yes many components suchasoverbandmagnets advancedlinersandcontrol systems can be retrofitted ontoexistinginfrastructure Our engineers can conductanauditofyourcurrentsetupandproposephasedupgradestoimproveperformanceandROI

Q4 Howdoyouquantifythepotentialmetalrecoveryimprovementbeforepurchases?
A5 We conductarepresentativesampletestingprograminvolvinglaboratoryscalecrushingandmagneticseparationonyoursuppliedslag This generatesametallurgicalbalancereportprojectingliberationratesandrecoverypotentialwithdifferentmachineconfigurations providinganevidencebased forecast

Q5 Whatistheleadtimefromordertocommissioningforastandardheavydutyslagcrushersplants?
A6 Forstandarddesignsintheheavydutyrange leadtimesaveragebetweenfivesevenmonths This includesmanufacturing factorytesting disassemblyforshipmentandreassemblyonyoursite Modularskiddedunits reduceonsiteassemblytimebyoverhalfcomparedtopiecebuilt plants