1. PAINPOINT DRIVEN OPENING

Managing slag, a challenging byproduct of metal production, directly impacts your plant’s bottom line and operational continuity. Are you facing these persistent challenges?
Unplanned Downtime: Frequent breakdowns of underengineered crushers halt your entire material handling chain, costing thousands per hour in lost processing time and labor.
Excessive Wear & Maintenance Costs: The highly abrasive nature of slag rapidly degrades standard crushing components, leading to unsustainable spending on replacement parts and maintenance labor.
Inconsistent Output & Bottlenecks: An illmatched crusher produces uneven particle size distribution, causing downstream screening inefficiencies and storage issues, ultimately delaying shipment to your customers.
High Operational Costs: Inefficient power consumption and the need for secondary or even tertiary crushing stages erode profit margins on what should be a valuable recycled product.

The central question for plant managers is: how do you transform this abrasive liability into a consistent, profitable stream without compromising reliability? The solution lies in specifying a purposebuilt slag crusher plant.

2. PRODUCT OVERVIEW

A slag crusher plant is a stationary or semimobile system engineered specifically to reduce large chunks of aircooled or granulated metallurgical slag into precisely graded aggregates. Unlike generic rock crushers, it is designed from the ground up to withstand extreme abrasion and intermittent tramp metal.

Operational Workflow:
1. Primary Receiving & Feeding: Slag is delivered via dump truck or loader into a robust hopper, often equipped with a grizzly feeder to bypass subsize material and protect the primary crusher.
2. Primary Size Reduction: A heavyduty jaw crusher or impact breaker performs the initial crushing, reducing large slabs to manageable diameters (typically <200mm).
3. Secondary Crushing & Screening: Material is conveyed to a secondary cone or impact crusher for further reduction. The crushed output is then screened via vibrating screens to separate product into specified size fractions (e.g., 05mm, 510mm, 1020mm).
4. Material Handling & Stockpiling: Onspec aggregate is conveyed to designated stockpiles for loading and transport. Oversize material is recirculated back to the secondary crusher in a closedloop system.

Application Scope: Designed for ferrous (blast furnace, steel) and nonferrous (copper, lead) slags. Ideal for integrated metal plants and standalone slag processing yards.
Limitations: Not suitable for primary ore processing or extremely hard igneous rock. Feed size must be controlled per plant design specifications.

3. CORE FEATURES

HeavyDuty AbrasionResistant Liners | Technical Basis: Highchrome white iron or manganese steel castings | Operational Benefit: Liner life increased by 60100% compared to standard materials, drastically reducing changeout frequency | ROI Impact: Lowers costperton for wear parts and reduces maintenance downtime by up to 30% annually.

Tramp Metal Protection System | Technical Basis: Hydraulic or pneumatic release mechanisms on crushers; metal detectors on feed conveyors | Operational Benefit: Prevents catastrophic damage from uncrushable metals mixed within slag | ROI Impact: Eliminates risk of major rotor or shaft damage, protecting a capital asset worth hundreds of thousands.

PLCBased Automated Control Panel | Technical Basis: Centralized programmable logic controller with load management and fault diagnostics | Operational Benefit: Enables singleoperator control, optimizes power draw, and provides clear alarm indicators for rapid troubleshooting | ROI Impact: Reduces labor requirements and minimizes unplanned stops through predictive alerts.

Modular SkidMounted Design | Technical Basis: Preassembled structural steel skids for major components | Operational Benefit: Significantly reduces civil works and onsite installation time by up to 40% | ROI Impact: Faster commissioning gets your revenuegenerating operation online sooner with lower initial construction costs.

HeavyDuty Vibrating Grizzly Feeder | Technical Basis: Robust feeder with adjustable grizzly bars for prescreening | Operational Benefit: Removes fines prior to primary crushing, increasing throughput efficiency and reducing unnecessary wear on the primary chamber | ROI Impact: Improves overall plant capacity by 1525% while lowering energy consumption per ton.

Enclosed Dust Suppression System | Technical Basis: Strategically placed spray nozzles at transfer points coupled with dust extraction vents | Operational Benefit: Maintains compliant airborne particulate levels, ensuring a safer working environment and meeting regulatory standards | ROI Impact: Avoids potential fines and work stoppages due to environmental noncompliance.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Generic Crusher Plant) | Our Slag Crusher Plant Solution | Advantage (% improvement) |
|||||
| Wear Part Life (Primary) | 3045 Days | 6090 Days | +100% |
| System Uptime Availability | 8085% | 9295% | +12% |
| Power Consumption/Ton | Baseline | Optimized motor loads & efficient drive design |18% |
| Finished Product Yield | Variable sizing requiring recrush Consistent grading within spec bands Recrush volume reduced by ~25% |
| Installation & Commissioning| 812 Weeks 57 Weeks 40% timetooperation |

5. TECHNICAL SPECIFICATIONS

Processing Capacity: Configurable from 50 TPH to over 300 TPH.
Feed Size Maximum: Up to 800mm slab size (model dependent).
Power Requirements: Total connected load typically ranges from 150 kW to 450 kW; designed for standard industrial voltage supply (400V/50Hz or customized).
Crusher Specifications: Primary jaw crusher sizes from 750x500mm up to 1200x1500mm; Secondary cone crushers with heavyduty mantle/bowl liners.
Material Specifications: Crusher housings in fabricated steel plate; Liners in Mn18Cr2 / HighChrome Alloy; Conveyor belts with high abrasionresistant covers.
Physical Dimensions (Typical Setup): Footprint approximately 40m (L) x 20m (W). Skid designs minimize foundation needs.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system rated for effective operation up to 80% relative humidity.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Recycling

Challenge: A major steel producer faced escalating landfill costs for blast furnace slag and needed an onsite solution creating saleable aggregate. Their existing equipment suffered weekly liner failures.
Solution Implementation of a turnkey slag crusher plant featuring primary jaw crushing followed by secondary cone crushing with automated screening.
Results Achieved consistent production of three aggregate grades within six weeks of commissioning. Wear part lifecycle extended from three weeks to seven weeks. The operation converted a cost center into a profit stream within one year.

Independent Slag Processing Contractor

Challenge A contractor processing slag from multiple sources required high mobility between sites without sacrificing durability or capacity.
Solution A semimobile skidmounted slag crusher plant, where primary and secondary modules could be relocated independently via lowloader trailers.
Results Reduced site setup time from three weeks to five days per location through prewired modules. Plant availability exceeded 93%, allowing the contractor to fulfill multiple longterm supply contracts reliably.

7. COMMERCIAL CONSIDERATIONS

Our solutions are offered in clear pricing tiers based on capacity:
Tier I (200 TPH): Fully customized highvolume systems with advanced automation options.

Optional features include magnetic separators for residual metal recovery automated greasing systems remote monitoring telemetry packages extended dust control enclosures

Service packages range from basic preventive maintenance plans comprehensive annual service contracts including wear part supply financing options are available including leaseto own structures equipment loans tailored support project cash flow

8.FAQ

What types of slag are suitable?
Designed primarily aircooled blast furnace basic oxygen furnace steel slags copper smelter slags Granulated slags may require specific feed arrangements due density

How does handle tramp metal?
Systems incorporate multiple protection layers including hydraulic release mechanisms primary jaw optional metal detectors feed conveyor automatically stop belt uncrushable object detected

What typical lead time delivery installation?
For standard configurations lead time manufacturing ranges months Complete delivery installation commissioning typically completed weeks following arrival site

Can integrate existing conveyors screens?
Yes plants engineered modular basis can interface existing downstream equipment provided specifications match Our engineering team will review layout compatibility

What ongoing maintenance requirements?
Daily visual checks lubrication Weekly bolt tightening inspections Scheduled liner replacements based monitored wear rates Predictive maintenance data provided via control system alerts