1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
Unreliable Processing: Inconsistent feed size and abrasive material cause frequent jams and unplanned downtime in standard crushers, halting your entire metal recovery or aggregate production line.
Excessive Wear Costs: The highly abrasive nature of slag leads to rapid deterioration of crusher liners, hammers, and screens, driving up your maintenance parts budget and labor hours.
Inefficient Liberation: Inadequate crushing fails to fully liberate metallic content from slag matrix, leaving valuable metal units unrecovered and reducing your overall yield and revenue.
Dust & Environmental Control: Dry processing generates significant fugitive dust, creating health hazards, environmental compliance risks, and site cleanliness issues.
Low System Throughput: A mismatched or undersized plant creates a bottleneck, preventing you from processing slag volumes at a pace that keeps up with upstream furnace or stockpile output.

What if your slag processing operation could achieve higher availability, predictable maintenance intervals, and maximized material yield? The solution lies in a purposeengineered slag crusher plant.

2. PRODUCT OVERVIEW

A modern slag crusher plant is a integrated system designed specifically for the size reduction and liberation of metallurgical slag (blast furnace, steel furnace). It transforms large, irregular slag feed into precisely graded aggregate for construction or efficiently liberates encapsulated metal for recovery.

Operational Workflow:
1. Primary Size Reduction: Large slag lumps (up to 11.5m) are reduced by a robust primary crusher (e.g., jaw crusher).
2. Magnetic Separation (Critical Stage): A powerful overhead magnetic separator extracts liberated ferrous metal from the crushed material stream for direct recovery.
3. Secondary Crushing & Screening: Remaining material is further reduced via a cone or impact crusher and screened into precise aggregate fractions (e.g., 05mm, 510mm, 1020mm).
4. (Optional) Tertiary Crushing/Final Screening: For specific highvalue aggregate products, a tertiary VSI crusher can shape the material for superior cubicity.

Application Scope & Limitations:
Scope: Ideal for integrated steel plants, smelters, scrap yards, and independent aggregate producers handling ferrous slags. Effective for both stationary installations and largescale temporary project sites.
Limitations: Not designed for nonferrous slags without significant magnetic system modification. Performance is contingent on proper feed regulation and preremoval of uncrushable debris (e.g., tramp metal beyond magnet capacity).

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: High manganese steel jaws with optimized nip angle | Operational Benefit: Handles large, irregular slag lumps without bridging or shockrelated failures | ROI Impact: Reduced primary stage downtime by up to 30%, ensuring continuous feed to downstream processes

Integrated Magnetic Separation System | Technical Basis: Selfcleaning crossbelt magnet with adjustable intensity | Operational Benefit: Automatically extracts liberated ferrous metal continuously from the crushing circuit | ROI Impact: Increases metal recovery rates by 1525%, converting waste into direct revenue

AbrasionResistant Liner & Component Package | Technical Basis: AR400/500 steel liners, ceramic wear tiles in chutes | Operational Benefit: Extends service life of wear parts in direct contact with abrasive slag | ROI Impact: Lowers costperton for wear parts by an average of 40% compared to standard mild steel

Enclosed Conveying & Dust Suppression | Technical Basis: Dusttight conveyor covers with spray nozzle systems at transfer points | Operational Benefit: Contains airborne particulate at source, maintaining a cleaner, safer site | ROI Impact: Mitigates environmental noncompliance risks and reduces housekeeping labor costs

Centralized PLC Control & Monitoring | Technical Basis: Automated process control with load management and fault diagnostics | Operational Benefit: Allows singleoperator oversight of the entire plant; prevents cascading failures | ROI Impact: Optimizes power consumption and improves overall plant efficiency by managing load peaks

Modular SkidMounted Design | Technical Basis: Preassembled modules on heavyduty structural skids | Operational Benefit: Significantly reduces onsite installation time and civil work costs | ROI Impact: Enables plant commissioning weeks faster than traditional fieldbuilt designs

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Basic Crushing Circuit) | Our Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Plant Availability (Uptime) | ~7580% due to wear/jam issues| Consistently >92% through robust design & protection systems| +15%+ operational time |
| Metal Recovery Efficiency| ~8590% with basic drum magnets| >97% with optimized magnetic separation placement & intensity| +8% recovered yield |
| Wear Part Life (Primary) | 6090 days in highly abrasive slag| 120180 days with specialized alloy & design| +100% lifespan increase |
| Total Power Consumption| Fixed speed drives across all motors| PLCmanaged variable frequency drives (VFDs) on feeders & conveyors| 20% energy use per ton |
| Installation & Commissioning Time| 812 weeks for civil works & assembly| 34 weeks for skid connection & commissioning| ~60% faster deployment |

5. TECHNICAL SPECIFICATIONS

Processing Capacity: Configurable from 50 TPH to over 300 TPH.
Feed Size: Accepts lump slag up to 1500mm edge length.
Final Product Sizes: Adjustable via screen configuration; typical ranges include 05mm sand substitute, 512mm chip, and +12mm drainage aggregate.
Power Requirements: Total connected load from 150 kW to 800 kW depending on plant scale; requires stable industrial threephase supply.
Key Material Specifications: Primary frame constructed from heavyduty structural steel (S355). Critical wear components in AR400/500 steel or equivalent highchrome alloys.
Physical Dimensions (Typical 150 TPH Plant): Approximate footprint of 35m (L) x 18m (W). Height varies per configuration (~12m).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust emission levels compliant with <10 mg/Nm³ at point of control.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Slag Processing

Challenge: A major steel producer needed to process granulated blast furnace slag into GGBS (ground granulated blast furnace slag) feedstock while maximizing recovery of residual iron. Their existing system suffered from low metal recovery and high conveyor belt wear from abrasion.
Solution: Implementation of a turnkey slag crusher plant featuring a highintensity magnetic drum separator postprimary crushing and enclosed abrasionresistant conveyors.
Results: Metal recovery increased to 98.5%, adding significant revenue stream. Conveyor belt life extended by over 200%. The consistent 10mm product improved downstream grinding mill efficiency by approximately 18%.

Construction Aggregate Producer – Steel Slag Aggregate

Challenge: An aggregate supplier faced market rejection due to inconsistent product gradation and the presence of unwanted metallic “floaters” in their processed steel slag aggregate.
Solution: Installation of a twostage crushing and screening plant with secondary magnetic separation before final screening decks.
Results: Product gradation consistency met DOT specifications consistently (>99% compliance). Postprocess metallic content was reduced to <0.1%, eliminating customer complaints. The producer accessed highervalue infrastructure projects.

7. COMMERCIAL CONSIDERATIONS

Our slag crusher plants are offered in three primary tiers:
1. Standard Configuration: Includes primary jaw crusher, magnetic separator, secondary impact crusher, basic screens, conveyors, and PLC control panel.
2. Enhanced Recovery Configuration: Adds scalping screen preprimary crusher tertiary VSI crusher for shaping advanced dust suppression system with bag filters
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Optional features include mobile trackmounted primary sections diesel power modules for remote sites automated lubrication systems remote monitoring telematics.

We offer comprehensive service packages:
Preventive Maintenance Plans
Wear Parts Kits with guaranteed inventory holding
Onsite operator training programs

Financing options including equipment leasing longterm rentalto own agreements are available subject to credit approval providing capital expenditure flexibility.

FAQ Section

Q1 Is your plant compatible with our existing material handling equipment?
Field data shows successful integration is standard practice Our engineering team will review your current conveyor heights discharge points electrical supply We provide all necessary interface drawings transition chutes

Q2 What is the expected operational impact during installation?
For skidmounted plants typical onsite hookup requires approximately two weeks of partial area shutdown Modular design minimizes disruption compared to traditional builds

Q3 How do you quantify the potential return on investment ROI?
ROI calculations are based on your specific throughput current metal loss rates maintenance costs energy consumption We provide detailed pro forma models showing payback periods typically between months based on increased yield reduced downtime lower costperton metrics

Q4 What are the commercial terms lead times?
Standard lead time is weeks following finalized design approval Payment terms typically involve progress payments tied major milestones like factory acceptance tests shipment Commercial contracts clearly define scope supply performance guarantees warranty provisions

Q5 Can you assist with permitting environmental compliance documentation?
Yes We provide comprehensive technical documentation including dust emission predictions noise level data general arrangement drawings specifically formatted support your local permit applications This has proven accelerate approval processes