1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
Low Throughput & High Downtime: Inefficient primary crushing creates a backlog, halting downstream processing and delaying material recovery. Every hour of unplanned downtime represents significant lost revenue.
Excessive Abrasion & Maintenance Costs: The highly abrasive nature of slag rapidly wears down standard crusher components, leading to frequent part replacements, high spare part inventories, and costly labor for unscheduled maintenance.
Unreliable Size Reduction: Inconsistent feed size and composition from slag heaps result in poor fragmentation. This causes chokeups, reduces crusher efficiency, and produces an uneven end product that hampers subsequent separation or sale.
High Operational Costs: The combined effect of energyinefficient crushing, constant maintenance, and process delays erodes your profit margin on recovered metal and aggregate.

Is your current slag processing system a source of recurring cost and disruption? A purposeengineered slag crusher plant directly addresses these pain points by transforming waste handling into a reliable, profitable recovery operation.

2. PRODUCT OVERVIEW

A modern slag crusher plant is a stationary or semimobile integrated processing system designed specifically for the size reduction and liberation of metallic fractions from steel, copper, or ferroalloy slag. It transforms raw slag feed into a consistently sized aggregate for sale or further processing.

Operational Workflow:
1. Primary Crushing: Large slag chunks (up to 1m³) are reduced to manageable sizes (typically <200mm) using a robust jaw crusher or impact breaker.
2. Secondary Crushing & Liberation: Material undergoes further reduction in a cone or impact crusher to liberate embedded metal beads from the mineral matrix.
3. Screening & Separation: Crushed material is screened into specified aggregate fractions (e.g., 05mm, 520mm). Liberated metal is recovered via magnetic separators.
4. Material Handling: Conveyors transport both the cleaned aggregate and recovered metal to designated stockpiles for dispatch.

Application Scope: Ideal for integrated steel plants, minimills, copper smelters, slag processing yards, and recycling contractors handling blast furnace (BF) slag, basic oxygen furnace (BOF) slag, electric arc furnace (EAF) slag, and nonferrous slags.

Limitations: Not designed for primary ore processing or extremely hard rock (>250 Mpa). Feed material must be free of explosive contaminants and oversized tramp metal beyond the system’s designed protection limits.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: High manganese steel jaws with optimized nip angle | Operational Benefit: Handles large, irregular slabs without bridging; withstands extreme shock loads | ROI Impact: Reduces primary breakdown time by up to 40%, lowering labor costs per ton processed.

Integrated Metal Separation | Technical Basis: Overband magnetic separator positioned postcrushing | Operational Benefit: Automatically extracts ferrous scrap from the crushed stream for direct sale | ROI Impact: Creates a secondary revenue stream; protects downstream equipment from metal damage.

AbrasionResistant Lining Systems | Technical Basis: Wearresistant steel plates in feed hoppers, chutes, and impact zones | Operational Benefit: Extends service intervals for highwear components by 23x | ROI Impact: Lowers annual spare parts expenditure and reduces maintenance downtime.

Centralized PLC Control System | Technical Basis: Automated process control with motor monitoring and fault diagnostics | Operational Benefit: Enables singleoperator oversight; provides clear alerts for jams or overloads | ROI Impact: Optimizes power consumption; prevents catastrophic failures through early intervention.

Modular SkidMounted Design | Technical Basis: Preassembled modules on heavyduty frames | Operational Benefit: Reduces onsite civil work and installation time by approximately 60% | ROI Impact: Faster commissioning leads to quicker return on investment; allows for future plant relocation.

Dust Suppression System | Technical Basis: Strategically placed spray nozzles at transfer points | Operational Benefit: Maintains compliant airborne particulate levels without slurry creation | ROI Impact: Avoids regulatory fines; preserves worker health and site cleanliness.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Our Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Tonnage Throughput| Standard aggregate crusher adapted for slag | Purposebuilt with reinforced rotors/jaws & optimized flow design| +1525% sustained throughput |
| Liner Wear Life| Standard manganese steel in critical zones| Multilayer wear packages with replaceable sections in all abrasion zones| +80120% extended service life |
| Metal Recovery Rate| Manual picking or postprocess magnetic separation| Inline magnetic separation integrated into crushing circuit| +95% ferrous recovery efficiency |
| Power Consumption per Ton| Fixedspeed drives across all motors| PLCcontrolled variable frequency drives (VFDs) on conveyors & fans| 1015% energy use |
| Mean Time Between Failure (MTBF)| Reactive maintenance schedules based on runtime| Predictive maintenance enabled by vibration & thermal sensors on major bearings| +30% increased MTBF |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to over 300 TPH of raw slag feed.
Power Requirements: Total connected load from 150 kW to 800 kW depending on configuration; standard supply at 415V/50Hz/3Phase (other voltages available).
Material Specifications: Primary crusher jaws manufactured from Mn18Cr2 alloy steel; liner plates from AR400/500 abrasionresistant steel; structural frames from heavyduty ISMB/ISMC sections.
Physical Dimensions (Typical Skid): Primary module approx. L12m x W4m x H5m. Full plant footprint varies with configuration.
Environmental Operating Range: Designed for ambient temperatures from 10°C to +45°C; dust protection rating of IP55 for electrical panels; can be equipped with coldweather or tropical packages as needed.

6. APPLICATION SCENARIOS

Steel Mill Slag Yard Retrofit | Challenge: A midsized steel mill faced chronic downtime due to abrasive wear in its aging crusher, causing pileup of LD slag and lost metal recovery revenue. Manual hammering was frequently required to clear jammed material.| Solution: Installation of a turnkey 120 TPH skidmounted slag crusher plant featuring an extraheavyduty jaw crusher and integrated overband magnet.| Results: Achieved consistent throughput of 120 TPH. Metal recovery increased by 22%. Annual maintenance costs decreased by an estimated 35% due to reduced wear part consumption.

Independent Slag Processing Contractor | Challenge: A contractor needed a mobile solution to process legacy slag piles at multiple sites but required higher capacity than typical mobile track plants offered.| Solution: Deployment of a semimobile modular slag crusher plant on portable skids, allowing relocation between sites with minimal reassembly.| Results: Plant was operational at a new site within one week of arrival. Processed over 150,000 tons across three sites with consistent product sizing, enabling premium pricing for clean aggregate.

7. COMMERCIAL CONSIDERATIONS

Our slag crusher plants are offered in clear pricing tiers based on capacity and robustness:

Standard Duty Plant (Up to 100 TPH): For processed EAF or granulated slag with consistent feed size.
HeavyDuty Plant (100 – 200 TPH): For mixed BF/BOF slags with higher abrasion potential; includes enhanced wear packages.
Extra HeavyDuty Plant (200+ TPH): For largevolume integrated mills; features duplex crushing stages and full automation.

Optional Features: Dust encapsulation cabins, metal scrap cleaning drums (for cleaner scrap), advanced metal detectors, automated greasing systems.
Service Packages: Extended warranty plans, annual inspection contracts guaranteed spare parts kits based on your projected tonnage.
Financing Options: We work with accredited partners to offer equipment leasing plans or term loans tailored to capital expenditure cycles common in metallurgical processing industries.

8. FAQ

1. Q: Is your plant compatible with our existing material handling equipment?
A: Yes. Our engineering team will review your current conveyor heights discharge points during the design phase Infeed hopper heights discharge conveyor trajectories are customized ensure seamless integration

2. Q What is the expected operational impact during installation commissioning?
A For skid mounted plants typical onsite installation electrical connection takes weeks Minimal disruption expected as most assembly testing is completed prior delivery

3 Q How do you guarantee the claimed wear life for components?
A Wear life projections are based historical data specific alloy specifications We provide guaranteed minimum tonnage figures for key wear parts backed commercial terms

4 Q What training provided for our operations maintenance staff?
A We include comprehensive onsite training covering normal operation routine maintenance troubleshooting safety procedures Documentation includes detailed manuals parts lists

5 Q Are there financing options available that align with our fiscal planning?
A Yes We offer several financing structures including operating leases capital leases term loans These can structured match cash flow generation from your recovered materials

6 Q Can the plant handle wet or sticky slag materials?
A While designed primarily dry processing we can incorporate specific design modifications such cascading feed systems non stick liners additional screening stages address challenging material characteristics

7 Q What is the lead time from order placement commissioning?
A Lead times vary capacity customization Typical lead time ranges months Standard configurations may be available shorter periods depending current production schedule