1. PAINPOINT DRIVEN OPENING

Managing slag, a highvolume, abrasive byproduct, presents distinct operational and financial challenges. Are you experiencing:
Excessive Downtime & Maintenance Costs: Frequent liner replacements and unplanned stops for crusher repairs due to slag’s extreme abrasiveness.
Inconsistent Throughput & Bottlenecks: Inadequate primary crushing creating a bottleneck, limiting downstream processing capacity and creating storage pile headaches.
High Operational Costs: Premature wear on conveyor systems from oversized, irregular feed material and excessive energy consumption from inefficient crushing cycles.
Product Quality Issues: Inability to reliably produce a consistent, sized aggregate for resale or further processing, leaving revenue on the table.
Space & Logistics Constraints: Bulky, stationary plants that are inflexible and costly to relocate as stockpile locations shift.

The core question is: how do you transform this challenging material from a disposal cost into a controlled, profitable stream while maximizing plant uptime?

2. PRODUCT OVERVIEW

A modern Wholesale Slag Crusher Plant is a heavyduty, semimobile or stationary crushing system engineered specifically for the primary and secondary reduction of metallurgical slag (blast furnace, steel furnace). It is designed not merely to break material, but to create an efficient, reliable workflow for hightonnage slag processing.

Operational Workflow:
1. Feed & PreScreening: Runofpile slag is fed via loader. An integrated grizzly or scalper removes fine material (50mm) bypassing the crusher, increasing effective capacity.
2. Primary Crushing: A robust jaw crusher or impactor performs the initial size reduction, accepting large slabs and delivering a consistent sub250mm product.
3. Secondary Crushing & Sizing: A cone crusher or further impactor takes the primary crushed material for final sizing to specification (e.g., 040mm aggregate).
4. Material Handling: Sized product is conveyed to designated stockpiles via heavyduty belt conveyors with impactresistant idlers.

Application Scope: Ideal for steel mills, slag processing yards, and aggregate producers handling blast furnace (BFS) or steel slag. Designed for continuous duty in highabrasion environments.

Limitations: Not suitable for wet, sticky materials without preprocessing. Maximum feed size is determined by the specific primary crusher model selected.

3. CORE FEATURES

HeavyDuty Primary Crusher | Technical Basis: Modified kinematics & premium manganese steel castings | Operational Benefit: Handles slablike slag pieces without bridging; withstands extreme abrasion with longer service intervals | ROI Impact: Reduces liner change downtime by up to 30% and decreases costpertonne for wear parts.

Integrated PreScalping Module | Technical Basis: Highamplitude vibrating grid or grizzly | Operational Benefit: Removes fines and subcrushsize material before the primary chamber | ROI Impact: Increases effective plant throughput by 1525% by preventing crusher choke and reducing unnecessary wear.

Centralized Greasing & PLC Control System | Technical Basis: Automated lubrication circuits with fault monitoring | Operational Benefit: Ensures critical bearings receive proper lubrication without manual intervention; provides operational diagnostics | ROI Impact: Prevents catastrophic bearing failures, extending major component life and simplifying maintenance planning.

Modular, SkidMounted Design | Technical Basis: Bolttogether substructures with integrated walkways and access platforms | Operational Benefit: Reduces civil foundation costs and allows for strategic relocation within a site as stockpiles move | ROI Impact: Cuts installation time by up to 40% compared to traditional stationary plants, improving capital deployment speed.

HeavyDuty Discharge Conveying System | Technical Basis: Impact beds, reinforced belts, and sealed rollers | Operational Benefit: Handles sharp, abrasive crushed slag without belt damage or excessive spillage | ROI Impact: Lowers conveyor maintenance costs and ensures continuous downstream material flow.

Dedicated Dust Suppression System | Technical Basis: Strategically placed nozzle arrays with solenoid control | Operational Benefit: Minimizes airborne particulate at transfer points during crushing operations | ROI Impact: Supports compliance with site environmental regulations, avoiding potential work stoppages.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average Jaw/Cone Plant) | Our Wholesale Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life in Slag Service (Primary) | 80,000 120,000 tonnes | 150,000 200,000 tonnes | +60% (based on premium alloys & optimized chamber design) |
| Effective Throughput (after scalping)| Based on crusher rating only| Crusher rating + 20% from fines removal| +20% system efficiency |
| Mean Time Between Failure (MTBF) Mechanical| ~450 hours| >700 hours| +55% reliability |
| Installation & Commissioning Time| 812 weeks| 46 weeks| 50% faster deployment |
| Total Cost of Ownership (5year projection)| Baseline| 1525% lower projected TCO| Significant longterm savings |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 150 to over 600 tonnes per hour.
Power Requirements: Total installed power typically 300kW 800kW depending on configuration; supplied via main grid connection or onboard generator module.
Feed Size: Accepts slab feed up to 1000mm x 800mm.
Final Product Size: Adjustable from 40mm down to <20mm based on screen/crusher settings.
Key Material Specifications:
Primary Crusher Liners: Manganese Steel (Mn18Cr2 / Mn22Cr2).
Frame Construction: Heavyduty welded steel plate (S355JR).
Conveyor Belting: ST2000+ rated with multiply abrasionresistant top cover.
Physical Dimensions (Typical Setup): Length ~35m; Width ~8m; Height ~7m (modular design allows variation).
Environmental Operating Range: Designed for 20°C to +45°C ambient temperature; dust suppression system rated for operation up to 85% relative humidity.

6. APPLICATION SCENARIOS

Steel Mill Slag Processing Yard | Challenge: A major steel mill faced escalating landfill costs for aged slag piles and needed to create a saleable construction aggregate. Existing equipment suffered daily breakdowns due to abrasion.| Solution: Implementation of a turnkey Wholesale Slag Crusher Plant featuring a heavyduty jaw crusher with integrated scalper and secondary cone crusher.| Results: The plant achieved consistent production of certified aggregate at 280 TPH. Wear part life increased by over twice the previous standard. Landfill costs were eliminated within 14 months of operation.

Independent Aggregate Producer Expanding Product Line | Challenge: An aggregate supplier sought entry into the slag aggregate market but required a flexible solution that could be relocated between multiple stockpile sites owned by different clients.| Solution:A semimobile skidmounted Wholesale Slag Crusher Plant was selected.| Results:The producer secured three separate processing contracts using the same plant unit. Relocation between sites was completed in under two weeks per move due to the modular design.

7. COMMERCIAL CONSIDERATIONS

Our Wholesale Slag Crusher Plants are offered in clear pricing tiers based on capacity and configuration:

Standard Tier (150300 TPH): Includes core primary crushing module with scalper PLC control basic dust suppression Ideal for lowervolume or dedicated singlesite operations
HighCapacity Tier (300600+ TPH): Includes primary jaw secondary cone/impactor advanced PLC automation comprehensive dust suppression Designed for maximum throughput continuous operation

Optional features include:
Magnetic separator modules
Onboard diesel generator power packs
Extended wear part packages
Advanced remote monitoring telematics

We offer comprehensive service packages from basic commissioning support up through full annual maintenance contracts including scheduled inspections parts supply priority support

Flexible financing options are available including equipment leasing longterm rentaltoown agreements project financing solutions tailored for capital expenditure planning

8. FAQ

1.Q What if our slag contains large amounts of scrap metal?
A Our standard configuration includes an overband magnetic separator installed above the discharge conveyor This effectively removes tramp metal protecting downstream conveyors Additional measures like reinforced components in key areas are recommended

2.Q How does this plant integrate with our existing screening equipment?
A The plant is designed as a standalone crushing circuit It can feed directly into your existing screens via its discharge conveyor The control system can be adapted to interface with your wider plant SCADA system if required

3.Q What is the expected energy consumption?
A Specific consumption varies but field data shows an average range of .08.12 kWh per tonne processed depending on final product size We provide detailed motor load analysis during project specification

4.Q What are typical payment terms?
A Standard commercial terms involve progress payments tied to key milestones such as order confirmation completion of manufacturing shipping arrival onsite commissioning final acceptance

5.Q How long does installation require?
A For our skidmounted plants typical installation including foundation preparation mechanical connection electrical hookup commissioning requires approximately four weeks assuming standard site conditions

6.Q Do you provide performance guarantees?
A Yes we provide guaranteed minimum throughput capacity based on defined feed material specifications as well as guaranteed maximum power consumption under load These are formalized in our commercial proposal

7.Q Who handles ongoing maintenance?
A We offer training programs for your maintenance crew Alternatively we can provide scheduled maintenance services through our network of field technicians ensuring optimal performance using genuine parts