1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
Unreliable Throughput & Downtime: Inconsistent feed size and tramp metal cause frequent jams in standard crushers, halting your entire material recovery line and delaying downstream processing.
Excessive Wear & Maintenance Costs: The highly abrasive nature of slag rapidly degrades standard manganese steel components, leading to unscheduled shutdowns and high spare part expenditures.
Inefficient Liberation of Valuables: Inadequate crushing fails to fully liberate metallic fractions (ferrous and nonferrous) from the slag matrix, leaving recoverable value in your waste stream and reducing overall plant revenue.
Dust & Environmental Control Issues: Dry crushing processes generate significant fugitive dust, creating environmental compliance risks and unsafe working conditions for personnel.

If these issues are impacting your profitability, the central question is: how do you achieve consistent, highvolume slag reduction with lower operational costs and maximized metal recovery? The answer lies in a purposeengineered Slag Crusher Plant.

2. PRODUCT OVERVIEW

A Slag Crusher Plant is a stationary or semimobile processing system specifically engineered for the primary, secondary, and sometimes tertiary crushing of metallurgical slag (blast furnace, steel furnace, copper, etc.). Its design prioritizes durability against abrasion and impact while ensuring efficient liberation of entrapped metals.

Operational Workflow:
1. Feed & PreScreening: Runofpile slag is fed via loader or conveyor into a vibrating grizzly feeder, which removes fine fractions (30mm) to bypass the primary crusher, increasing system efficiency.
2. Primary Crushing: Oversize material is reduced by a heavyduty jaw crusher or impactor designed for high compressive strength feed.
3. Metal Separation & Secondary Crushing: The crushed product typically passes over an overhead magnetic separator to remove liberated ferrous scrap. The remaining material is further reduced by a cone crusher or secondary impactor to achieve the target grain size (e.g., 20mm).
4. Sizing & Stockpiling: A final vibrating screen classifies the product, with oversize material recirculated. Onspec material is conveyed to stockpile for sale as aggregate or for further processing.

Application Scope: Ideal for integrated steel plants, smelters, slag processing yards, and aggregate producers handling ferrous and nonferrous slags.

Limitations: Not designed for primary mining of virgin rock or for processing materials with extreme moisture or clay content without preconditioning.

3. CORE FEATURES

HeavyDuty Vibrating Grizzly Feeder | Technical Basis: Highstrength eccentric shaft drive | Operational Benefit: Removes fines upfront, regulates feed to the primary crusher preventing chokefeeding | ROI Impact: Reduces primary crusher load by up to 30%, lowering wear and energy consumption per ton processed.

AbrasionResistant Liner Packages | Technical Basis: Airhardening manganese steel or composite ceramic/metal alloys | Operational Benefit: Liner life extended by 4060% compared to standard manganese in highabrasion zones | ROI Impact: Decreases downtime for liner changes and reduces annual spare parts inventory cost.

Integrated Magnetic Separation Circuit | Technical Basis: Overband selfcleaning magnets positioned at optimal discharge points | Operational Benefit: Continuously extracts liberated ferrous metal during crushing stages | ROI Impact: Creates a direct revenue stream from scrap recovery and protects downstream conveyors and crushers from metal damage.

Centralized Greasing & Hydraulic Systems | Technical Basis: Automated lubrication points for bearings and hydraulic adjustment/tramp release systems | Operational Benefit: Ensures critical components are lubricated under all operating conditions; allows quick clearing of uncrushables | ROI Impact: Prevents catastrophic bearing failures (a major cause of downtime) and minimizes manual maintenance intervention time.

Dust Suppression System Integration | Technical Basis: Nozzle arrays at transfer points connected to water supply with solenoid control | Operational Benefit: Effectively controls dust emissions at source during crushing operations | ROI Impact: Mitigates environmental noncompliance risks and reduces housekeeping labor costs.

Robust Structural Fabrication | Technical Basis: Stiffened frame design with heavyduty crawler or fixed plant support legs | Operational Benefit: Maintains alignment under continuous highvibration loads over years of operation | ROI Impact: Eliminates costly structural repairs and prevents premature failure of mounted components due to frame flexing.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Our Slag Crusher Plant Solution | Advantage (% improvement) |
| : | : | : | : |
| Availability / Uptime | 8085%, frequent jamming from tramp metal >8592%, hydraulic tramp release clears uncrushables in 8% increase |
| Liner Life in Primary Stage (Mn Steel) ~40,000 MT throughput ~60,000 MT throughput >50% improvement |
| Specific Power Consumption ~0.8 1.0 kWh/ton ~0.65 0.75 kWh/ton >20% reduction |
| Metal Recovery Efficiency Manual picking postcrushing Inprocess magnetic separation at 2 stages Scrap recovery yield increased by 1525% |
| Dust Emission at Transfer Points Dry crushing with local extraction Wet suppression system at source PM10 emissions reduced by >90% |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to over 300 TPH processed slag.
Power Requirements: Total installed power typically ranges from 150 kW (for 50 TPH plant) to 450 kW (for 300 TPH plant), dependent on configuration.
Material Specifications: Primary crusher jaws/liners manufactured from premiumgrade Manganese Steel (1822%). Critical wear plates utilize AR400 steel. Structural frames fabricated from heavyduty ISMC/ISMB sections.
Physical Dimensions (Typical 150 TPH Plant): Length (~25m) x Width (~8m) x Height (~7m). Available in fixed skidmounted or semimobile trailer versions.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust suppression system requires clean water supply at 3040 PSI; consumption approx. 50 liters per ton crushed.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Challenge:

A major steel producer faced inconsistent feed from aged stockpiles causing daily chokeups in their existing crusher, limiting aggregate production to just one shift per day due to maintenance needs.

Solution:

Implementation of a turnkey Slag Crusher Plant featuring an extradeep crushing chamber jaw crusher with hydraulic toggle adjustment for quick CSS changes, paired with a powerful overhead magnet on the primary discharge belt.

Results:

Plant availability increased to three full shifts. Aggregate production rose by 210%. Recovered ferrous scrap generated sufficient revenue to cover the plant’s operating labor costs annually.

Copper Smelter Tailings Reprocessing Challenge:

A smelter sought to recover residual copper from old dump slag but found that conventional hammer mills created excessive fines (3mm), rendering gravity separation ineffective.

Solution:

A twostage Slag Crusher Plant using a jaw crusher followed by a cone crusher in closed circuit with a screen was deployed for controlled size reduction targeting 12mm+3mm.

Results:

The optimized grain size distribution improved recovery rates in the downstream jig plant by over 18%. The robust design handled the highly abrasive silicarich slag with liner life meeting projected targets.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Solutions are projectspecific but generally fall into three categories:
Standard SkidMounted Plant (50100 TPH): A costeffective entry point for lower volume processors.
Modular MediumCapacity Plant (100200 TPH): The most common configuration offering optimal balance of output and investment.
HighCapacity Fixed Stationary Plant (200300+ TPH): Designed for largescale producers requiring maximum uptime and automation.
Optional Features: Vibrating feeder vs apron feeder; secondary cone vs impact crusher; automated metal detection system; advanced PLC control panels with remote monitoring capability; sound enclosures.
Service Packages: Extended warranty plans; annual inspection contracts; guaranteed spare parts delivery schedules (e.g., 48hour critical parts availability).
Financing Options: Equipment leasing structures through partner financial institutions; milestonebased project payment plans for turnkey installations.

8. FAQ

1. Is your Slag Crusher Plant compatible with our existing conveyors and material handling infrastructure?
Our engineering team can design transfer heights and discharge points to match your current layout during the project specification phase.

2. What is the expected operational noise level?
With standard equipment enclosures, field measurements typically show levels below 85 dB(A) at a distance of one meter from the machinery when processing dry slag.

3. How long does installation take?
For a skidmounted plant delivered preassembled on our frames, onsite commissioning can be completed within two weeks after foundation readiness upon arrival at your site

4.Can you provide performance guarantees?
Yes we offer guaranteed minimum throughput capacity based on defined feed material characteristics as well as maximum power consumption per ton

5.What are typical payment terms?
For custom plants terms are generally structured as follows
30% advance payment
60% against dispatch
10% after successful commissioning

6.Do you offer training for our operators
Comprehensive training covering operation routine maintenance safety procedures troubleshooting is provided onsite during commissioning

7.How do you handle warranty claims
We maintain regional service hubs Warranty claims initiate through our service manager who coordinates diagnostics part dispatch if needed technician deployment if required