1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
Unreliable Throughput: Inconsistent crusher performance creates pileup at the furnace or converter, delaying upstream processes and forcing costly production pauses.
Excessive Downtime: Frequent mechanical failures, wear part changes, and unplanned maintenance halt your entire material recovery line, costing thousands per hour in lost processing time.
High Operational Costs: Premature wear on crusher jaws, liners, and rotors from abrasive slag leads to soaring spare part inventories and labor expenses.
Inconsistent Product Grading: Poorly sized output material complicates downstream magnetic separation or screening, reducing metal recovery rates and the market value of your aggregate byproduct.
Space & Integration Headaches: A plant that isn’t designed for your site’s footprint or material flow creates inefficiencies in handling, increases dust, and limits future expansion.

The central question is: how do you transform this costly byproduct stream into a reliable, profitable operation with minimal intervention? The answer lies not just in a machine, but in a system engineered from the ground up for your specific duty.

2. PRODUCT OVERVIEW

A Slag Crusher Plant is a turnkey system designed for the primary, secondary, and sometimes tertiary crushing of metallurgical slag (blast furnace, steel furnace). It transforms large, irregular slag feed into a controlled, sized aggregate for efficient metal recovery and saleable construction material.

Operational Workflow:
1. Feed & PreScreening: Runoffurnace slag is fed via loader or conveyor. An initial grizzly or scalper screen removes fine fractions to bypass the primary crusher.
2. Primary Size Reduction: A heavyduty jaw crusher or impact breaker reduces large slabs (often up to 1000mm) to manageable sizes (typically under 200mm).
3. Metal Separation & Secondary Crushing: The crushed material passes over an overhead magnetic separator to extract liberated ferrous metal. Remaining material is conveyed to a secondary cone or impact crusher for final sizing.
4. Final Screening & Stockpiling: A vibrating screen classifies the output into precise product fractions (e.g., 05mm, 520mm, 2040mm) for market or further processing.

Application Scope: Designed for integrated steel plants, smelters, foundries, and standalone slag processing yards handling ferrous slags.

Limitations: Not suitable for primary mining of virgin rock; feed must be within designated maximum size and hardness (typically Mohs 78 for slag). Nonferrous slag processing may require different separation technology.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: Reinforced frame & kinematics optimized for high shock loads from slabby slag | Operational Benefit: Sustained throughput with minimal frame stress or fatigue cracking | ROI Impact: Extended structural lifespan reduces risk of catastrophic failure and associated capital replacement costs.

Integrated Magnetic Separation | Technical Basis: Overband selfcleaning magnets positioned at optimal discharge points | Operational Benefit: Continuous extraction of pure metallic fraction directly during crushing stages | ROI Impact: Maximizes metal yield recovery—often by 38%—directly improving revenue from scrap sales.

AbrasionResistant Material Flow | Technical Basis: Hardoxlined hoppers, AR steel plate chutes, and ceramiclined wear zones at impact points | Operational Benefit: Dramatically reduced maintenance intervals for flowpath components | ROI Impact: Lowers annual wear part expenditure by up to 40% and reduces liner change downtime.

Centralized PLC Control System | Technical Basis: Automated sequencing with load management and fault diagnostics | Operational Benefit: Enables operation by a single controller with clear visibility over all plant functions | ROI Impact: Optimizes power consumption per ton crushed and reduces labor requirements for monitoring.

Modular Skid/Module Design | Technical Basis: Preassembled structural modules with integrated walkways and maintenance access | Operational Benefit: Significantly faster onsite installation and commissioning (weeks vs. months) | ROI Impact: Reduces civil works cost by up to 30% and accelerates timetorevenue from project start.

Dust Suppression System Integration| Technical Basis: Nozzle arrays at transfer points matched to fanpowered extraction where required| Operational Benefit: Maintains site environmental compliance and protects worker health| ROI Impact: Avoids regulatory fines and reduces longterm equipment wear caused by abrasive dust ingress.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Slag Plant | Our OEM Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability / Uptime| ~85%, frequent unplanned stops| >92%, via robust design & predictive maintenance access| +8% operational time |
| Tons Per Hour Consistency| Fluctuates ±15% with feed variation| Maintains within ±5% via optimized feed regulation & crusher controls| +10% throughput stability |
| Wear Cost per Ton Processed| Based on standard manganese steel| Reduced through targeted use of premium alloys & ceramic liners| 25% to 40% |
| Metal Recovery Rate| Passive separation postcrushing| Active extraction at multiple crushing stages| +3% to +8% yield improvement |
| Installation & Commissioning Time~1624 weeks onsite~1014 weeks with modular design|30% to 40% faster deployment |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to over 300 TPH of bulk slag.
Feed Size Maximum: Up to 1000mm x 1200mm slab form.
Power Requirements: Plant total connected load typically between 250kW – 800kW depending on configuration; designed for 415V/3Phase/50Hz or customer specification.
Material Specifications: Primary crusher frames in hightensile steel; liners in Mn18Cr2 or equivalent; wear plates in Hardox 400/500; chutework in abrasionresistant (AR) steel plate.
Physical Dimensions (Typical Layout): Modular design adaptable to site; typical footprint length ranges from 40m to 70m including stockpile conveyors.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust emission control achieves <10 mg/Nm³ at point of generation with integrated system.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Slag Granulation Feedstock

Challenge A major steel producer needed consistent sub30mm aggregate for their granulation plant but faced constant jamming in their old doubletoggle jaw crusher from sticky slag masses.
Solution Implementation of a custom Slag Crusher Plant featuring a deepchamber primary impactor with hydraulic assist for clearing blockages.
Results Throughput stabilized at constant180 TPH; blockages eliminated through automated reversal cycles; granulation plant efficiency improved due to consistent feed size.

Independent Slag Processing Contractor – Multiple Source Materials

Challenge A processor handling diverse slags from various mills experienced high secondary cone crusher mantle wear costs due to uncrushable tramp metal passing initial separation.
Solution A threestage plant was designed with two stages of magnetic separation—precrush scalping plus postprimarycrush extraction—and an automated metal trap before the cone crusher.
Results Tramp metal incidents reduced by over95%; cone crusher liner life extended by60%; final aggregate quality improved significantly for highervalue applications.

MiniMill – EAF Slag Processing

Challenge Limited site space prevented a traditional linear crushing circuit layout neededfor their expanding Electric Arc Furnace output.
Solution A compact vertical layout Slag Crusher Plant using skidmounted primaryand secondary units stackedwith radial stacker conveyors was engineered.
Results The plant fit into50% less floor area than conventional designs while meeting150 TPH requirement; modular design allowed future relocation as site layout evolved.

7. COMMERCIAL CONSIDERATIONS

Our approach provides clarity on investment:
Equipment Pricing Tiers:
Base Configuration (Primary Crushing + Basic Separation): For operations focused solely on size reduction prior to external processing.
Standard Configuration (TwoStage Crushing + Full Magnetic Recovery): Our most common solution offering balanced CAPEX/OPEXfor full metal recoveryand aggregate production
Premium Configuration (MultiStage Crushing+ Advanced Screening+ Full Automation): For highvolume producers requiring maximum product flexibilityand minimal manpower

Optional Features include:
Onboard diesel generator setsfor remote sites
Advanced water spray systemsfor dust control
Metal fragmentizer systemsfor densemedical ball purification
Complete electrical house(EHouse)for simplified wiring

Service Packages rangefrom annual inspection planswith guaranteedwear part kits tooffsite monitoring supportand fulloperationandmaintenance contracts

Financing Options can be discussed including leasetoown structuresor productionlinked repayment models aligning investment costswith operational cash flow

FAQ

What are the key factors determining whether I need a jawor impactcrusheas my primary unit?
The choice hinges primarilyon feed characteristics Jawcrushers excelon very slabby densefeed where compression strengthis critical Impactcrushers offer better reduction ratiosand handle moderately slabby material well oftenat lower initial cost We analyzeyour specificslag samplesand feed sizeto recommendthe optimaltype

How doesan OEM factorydesignedplant differfrom piecing together individualcrushers myself?
An OEMdesignedSlag CrushePlant ensuresall componentsare matchedfor capacity wear protectionand flow eliminatingbottlenecks It includesintegrated safety access platforms dust control wiring anda singlecontrol system This holisticapproach delivershigher reliability lower operatingcost per tonand singlesource accountability

Can this plantbe integratedwith our existingconveyorsandscreening equipment?
Yes integrationis standard practice We conducta full review ofyourexisting infrastructureto designinterfacing modules that connectto your current system maximizingyourearlier investmentwhile upgradingthe corecrushing andrecovery process

What isthe typicalimplementation timelinefrom orderto commissioning?
Fora standardconfiguration leadtimeis approximately18–22 weeks Followingorder confirmation Detailed engineeringrequires4–6 weeks shopfabricationtakes10–12 weeks onsiteinstallationand commissioningtypicallyrequires2–4 weeks Modular designs significantlyreduceonsite labor time

What kindof aftersalessupportcan we expect?
Support includesdetailedoperational trainingforyour team comprehensive manuals spare parts recommendationswith stocking programsand remote diagnostic support Service engineersare availablefor scheduledmaintenanceor technicalassistance Field data showsplanned maintenancecontractscan reduceunplanned downtimeby over70%

Are there financingoptions availableforthe completeplant?
Yes we workwith severalindustrial equipmentfinancing partners Options includecapitallease operatingleaseor loan agreements Structurescan oftenbe tailoredto matchprojectedcash flowsfrom themetal recoveryand aggregatesales generatedbythe plant

How doyou ensurethe plantmeetsour local environmentalregulations fordust& noise?
Our designsincorporate internationallyrecognizedcontrol standards Wet suppression systemsare sizedbasedon throughput Noise attenuationmeasures includeacoustic enclosuresfor key drives We provideall necessarytechnicaldocumentationto supportyour permitapplications