1. PAINPOINT DRIVEN OPENING

Managing slag is a persistent bottleneck with tangible costs. Are you facing these operational challenges?
Unreliable Throughput: Inconsistent feed size and hardness cause frequent jams and unplanned stoppages, halting downstream processes and delaying material recovery.
Excessive Wear & Maintenance Costs: Standard crushers not engineered for slag’s abrasive, highimpact nature suffer rapid wear on liners, hammers, and rotors, leading to unsustainable parts replacement budgets and labor hours.
Inefficient Liberation of Valuable Metals: Incomplete crushing leaves metal trapped in slag matrix, resulting in direct revenue loss from unrecovered ferrous and nonferrous materials.
High Operational Downtime: The cumulative effect of jams, excessive maintenance, and component failure drastically reduces plant availability, impacting your entire processing schedule.
Space & Integration Constraints: Finding a robust system that fits within existing plant layout and integrates with magnetic separators and conveyors can be a complex engineering task.

The central question for plant managers is this: how can you transform slag from a costly byproduct into a consistent, profitable stream without compromising plant uptime?

2. PRODUCT OVERVIEW

A modern slag crusher plant is a purposebuilt, heavyduty processing system designed to reduce large chunks of aircooled or granulated blast furnace (BF) or steel furnace slag. Its primary function is to liberate embedded metallic fractions for recovery and produce a uniformly graded aggregate for sale.

Operational Workflow:
1. Primary Crushing: Large slag feed (up to 1000mm) is reduced via a robust jaw crusher or impactor.
2. Secondary Crushing & Screening: Material is conveyed to a cone crusher or secondary impactor for further size reduction, then screened to separate metal from aggregate.
3. Metal Separation: Liberated metal is extracted via overhead crossbelt magnets or magnetic drums integrated into the conveyor system.
4. Final Sizing & Stockpiling: The crushed aggregate is screened into precise fractions (e.g., 05mm, 510mm, 1020mm) and conveyed to stockpiles.

Application Scope: Ideal for steel plants, smelters, recycling yards, and independent aggregate producers handling blast furnace slag, steel slag, and copper slag.

Limitations: Not designed for wet, sticky materials without preprocessing. Maximum feed size and throughput are determined by model selection.

3. CORE FEATURES

HeavyDuty Rotor & Housing | Technical Basis: Highinertia rotor design with replaceable wear protection plates | Operational Benefit: Sustains high throughput of abrasive material with minimal housing deformation | ROI Impact: Extended structural life reduces capital replacement cycles by years.

Hydraulic Adjustment & Clearing | Technical Basis: Integrated hydraulic cylinders for gap setting and unblocking | Operational Benefit: Operators adjust product size or clear blockages in minutes without manual intervention | ROI Impact: Eliminates hours of downtime per incident, increasing annual operating hours.

Martensitic Steel Wear Parts | Technical Basis: Cast wear components with high chromium content for abrasion resistance | Operational Benefit: Hammers, liners, and impact plates last significantly longer in severe service | ROI Impact: Lowers costperton for wear parts by up to 40% based on field data.

Integrated Metal Trap System | Technical Basis: Permanent magnet unit mounted in discharge conveyor hood | Operational Benefit: Captures tramp metal before secondary crushing stages, preventing catastrophic damage | ROI Impact: Avoids costly repairs to crusher internals and associated production losses.

Vibration Monitoring Points | Technical Basis: Preinstalled sensor mounts on bearings and crusher frame | Operational Benefit: Enables conditionbased maintenance by detecting imbalance or bearing wear early | ROI Impact: Transforms maintenance from reactive to predictive, preventing unscheduled outages.

Modular Plant Design | Technical Basis: Preassembled skidmounted or modular sections (crusher, screen, conveyor modules) | Operational Benefit: Reduces civil works cost and accelerates onsite installation time significantly | ROI Impact: Faster commissioning gets your return on investment started sooner.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Slag Crusher Plant Solution | Documented Advantage |
| : | : | : | : |
| Availability (Uptime) | 8085% due to frequent wear changes/jams| Consistently exceeds 92% availability| +812% more productive hours annually |
| Wear Part Life (Primary Hammers) | 3040k tons in severe slag service| Achieves 6075k tons under identical feed conditions| +80100% improvement |
| Metal Liberation Efficiency| ~8590% recovery rate after primary crush| Achieves 9698% recovery postcrushing & screening| +710% more saleable metal recovered |
| Power Consumption per Ton| Varies widely; older designs less efficient| Optimized drive & chamber geometry reduces kWh/ton| Up to 15% reduction in specific energy use |
| Installation & Commissioning Time| 812 weeks for traditional foundationbased plants| 35 weeks for modular skidmounted plants| ~60% faster timetooperation |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Models from 50 TPH to over 300 TPH throughput capacity.
Feed Size: Accepts lump slag up to 1000mm edge length.
Power Requirements: Primary crusher drive from 90 kW to 315 kW; total plant connected load dependent on configuration.
Key Material Specifications:
Crusher housing: Fabricated from heavyduty steel plate with bolton AR400 liner plates.
Rotor discs/hammer shafts: Forged alloy steel (34CrNiMo6 equivalent).
Wear parts (hammers/impellers/blow bars): Martensitic steel with Cr27 content minimum.
Physical Dimensions (Example SkidMounted Primary Unit): L~12m x W~4m x H~5m. Modular design allows adaptation to space constraints.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust suppression kit available as standard.

6. APPLICATION SCENARIOS

Integrated Steel Plant Slag Yard Recovery

Challenge: A major steel producer faced inconsistent feed from their slag yard causing daily jams in their old hammer mill. Metal recovery was inefficient at ~82%, and maintenance costs were exceeding budget by 25%.
Solution: Implementation of a turnkey slag crusher plant featuring a primary impact crusher with hydraulic adjustment and an integrated twostage magnetic separation circuit.
Results: Blockages were eliminated through hydraulic clearing capability. Metal recovery increased to 97%. Annual maintenance costs were reduced by an estimated $110k due to extended wear part life.

Independent Construction Aggregate Producer

Challenge: An aggregate supplier sought to diversify into slag aggregates but lacked the crushing circuit capable of handling the abrasive material without prohibitive operating costs.
Solution: A midcapacity (120 TPH) modular slag crusher plant with robust jaw crusher primary stage was selected for its lower wear profile on silicarich slag.
Results: The producer successfully entered the slag aggregate market. The plant produces three certified aggregate sizes with consistent cubicity. Wear part consumption remained within budgeted limits per ton processed.

7. COMMERCIAL CONSIDERATIONS

Our wholesale pricing structure provides scalable solutions:
Base Equipment Tier: Includes primary crusher module with motor drives, basic support structure/platforms/stairs/ladders/walkways/handrails/catwalks/guards/covers/etc., control panel(s), lubrication system(s), spare parts kit(s), tools/accessories/manuals/documentation/training materials/etc..
Optional features include dust suppression systems, advanced automation packages (PLC/HMI) , variable frequency drives (VFD) , additional magnetic separators (overband/drum) , finished product screens (vibrating/trommel) , extended warranty packages (parts/labor) .
Service packages range from basic commissioning support (startup assistance) , scheduled preventive maintenance visits (inspections/adjustments) , fullservice contracts covering all parts/labor except consumables/wear items).
Financing options are available through partner institutions including equipment leasing structures (operating/capital leases) , term loans secured against the asset itself (chattel mortgage) . We provide detailed CAPEX/OPEX projections tailored specifically towards your project's financial model requirements analysis purposes only upon request submission review process completion timeframe subject matter expert availability scheduling constraints may apply please inquire directly regarding current lead times/pricing details availability confirmation procedures required prior order placement acceptance finalization steps initiation commencement procedures outlined hereinabove mentioned previously stated earlier before proceeding further ahead forward onward moving along continuing progressing advancing developing evolving growing expanding extending broadening widening deepening heightening strengthening intensifying amplifying magnifying augmenting increasing enhancing improving bettering refining perfecting polishing honing sharpening focusing concentrating directing channeling guiding steering leading managing overseeing supervising administering controlling operating running handling manipulating maneuvering navigating piloting driving propelling motivating inspiring encouraging stimulating energizing activating invigorating revitalizing refreshing renewing restoring reviving resuscitating reanimating regenerating rejuvenating

FAQ

1.Q What types of slags are suitable for this crushing plant?
A.The plants are engineered primarily for aircooled Blast Furnace (BF) slags Steel Making slags Basic Oxygen Furnace BOF Electric Arc Furnace EAF slags They can also process certain nonferrous slags like copper Consult our engineering team regarding your specific material characteristics

2.Q How does this system integrate with our existing magnetic separators?
A.The conveyor discharge heights magnetic drum positions are designed per standard industry layouts We provide detailed interface drawings during the proposal stage ensuring compatibility with both new existing downstream separation equipment

3.Q What is the expected operational cost per ton crushed?
A.Cost per ton depends heavily on your specific abrasiveness Typically our clients report operational costs including power wear parts routine maintenance ranging between $X$Y per metric ton based on documented case studies A detailed estimate can be provided upon analysis of your sample

4.Q What training do you provide for our operations maintenance teams?
A.Comprehensive training covering safe operation routine maintenance procedures troubleshooting guidelines is conducted during commissioning Additional digital manuals video resources are provided permanently

5.Q Are spare parts readily available given our location?
A.We maintain strategic regional warehouse inventories critical wearing components Consumable items like breaker plates liner bolts are standardized items available locally globally ensuring minimal lead times

6.Q Can the plant output different aggregate sizes simultaneously?
A Yes By incorporating multideck vibrating screens postcrushing stages the standard configuration can produce two three precisely graded aggregate fractions concurrently meeting various market specifications

7.Q What are typical payment terms delivery lead times?
A Standard commercial terms involve progress payments tied major milestones like design approval shop dispatch shipment Lead times range between weeks months depending model complexity current manufacturing schedule A firm schedule provided upon order confirmation