1. PAINPOINT DRIVEN OPENING

Are you managing a slag processing operation burdened by persistent bottlenecks and unpredictable costs? The challenges of handling abrasive, variablecomposition slag directly impact your bottom line. Consider these common operational hurdles:

Premature Wear & Unplanned Downtime: Standard crushers rapidly deteriorate under the extreme abrasiveness of metallurgical slag, leading to frequent component replacement and costly, unscheduled production stops.
Inconsistent Throughput & Product Quality: Fluctuations in slag feed size and hardness can choke conventional plants, causing output volatility and an unreliable final aggregate gradation that fails to meet specification.
High Operational & Maintenance Costs: Excessive energy consumption per ton processed, combined with laborintensive maintenance routines for liner changes and clearance adjustments, erodes profit margins.
Space & Mobility Constraints: Fixed crushing installations lack flexibility for multisite projects or evolving yard layouts, locking you into a single, often inefficient, material flow.

Is your current setup delivering the consistent tonnage, product quality, and costperton metrics required to stay competitive? The solution lies in a purposeengineered system designed from the ground up for the unique demands of slag reduction.

2. PRODUCT OVERVIEW

The Wholesale Slag Crusher Plant is a heavyduty, stationary or semimobile crushing system engineered specifically for the primary and secondary reduction of blast furnace (BF) slag, steel slag, and nonferrous slags. It transforms large, irregular slag feed (often up to 1m in size) into precisely graded aggregates for use in construction, cement additives, or road base materials.

Operational Workflow:
1. Primary Reduction: Dumpfed or loaderfed slag is introduced into a robust primary jaw crusher or impactor, breaking down large lumps to a manageable size.
2. PreScreening & Bypass: A grizzly or scalping screen removes fine material (030mm) prior to secondary crushing, boosting overall plant efficiency and reducing crusher wear.
3. Secondary Crushing & Shaping: The precrushed material is conveyed to a secondary cone crusher or impact crusher for further size reduction and cubical product shaping.
4. Final Screening & Classification: Material is screened into multiple specified fractions (e.g., 05mm, 510mm, 1020mm) via highcapacity vibrating screens.
5. Stockpiling & Recirculation: Onspec material is conveyed to stockpiles. Oversize material is automatically recirculated back into the secondary crusher circuit.

Application Scope: Ideal for integrated steel plants, standalone slag processing contractors, and largescale construction material producers handling between 50600 tons per hour.

Limitations: Not designed for primary rock mining operations with higher compressive strengths (>250 MPa) or for processing wet, sticky materials without prior drying or specific feeder modifications.

3. CORE FEATURES

HeavyDuty Primary Breaker | Technical Basis: Reinforced manganese steel jaws/impactor bars with optimal nip angle | Operational Benefit: Sustained performance under high shock loads from large,dense slag pieces; reduces bridging and feed issues | ROI Impact: Extended service life reduces liner change frequency by an estimated 3040%, lowering parts inventory and labor costs.

AbrasionResistant Circuit Design | Technical Basis: Strategic use of wearresistant liners in hoppers, chutes,and conveyor transfer points; hardened alloy blow bars/cones | Operational Benefit: Maintains material flow integrity and protects critical components from accelerated degradation | ROI Impact: Minimizes maintenance downtime and replacement part expenditure,directly improving plant availability.

Intelligent Discharge System | Technical Basis: Hydraulic or mechanical adjustment of crusher discharge setting with centralised control | Operational Benefit: Allows operators to finetune final product size in minutes without stopping the plant,in response to changing feed or product demands | ROI Impact: Enables rapid product switching to capture premium market prices,maximising revenue from processed slag.

Integrated Metal Separation | Technical Basis: Overbelt magnetic separators installed at key transfer points postcrushing | Operational Benefit: Automatically extracts residual ferrous metal (tramp iron) from the aggregate stream,purging contaminants that damage downstream equipment | ROI Impact: Protects conveyors and final product purity,increasing product value and eliminating manual recovery labor.

Centralised Greasing & Monitoring | Technical Basis: Automated lubrication systems for all major bearing points with lowlevel alerts | Operational Benefit: Ensures optimal bearing health under highdust conditions; reduces manual lubrication tasks and associated risks | ROI Impact: Prevents catastrophic bearing failures,a leading cause of extended unplanned downtime,and reduces routine maintenance manhours.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Generic Aggregate Plant) | Wholesale Slag Crusher Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Life in Primary Stage| 6090 days on abrasive slag | 120180 days with specialized alloys/designs| +100% improvement |
| Tons Processed per kWh| Lower efficiency due to improper chamber design| Optimized kinematics reduce power draw per ton| +1525% energy efficiency |
| Product Yield within Spec| Variable yield due to nonoptimized flow| Highprecision screening & recirculation ensures consistency| +1015% more saleable product |
| Mean Time Between Failure (MTBF)| Frequent stoppages for wear part adjustment/change| Robust design & accessible components increase reliability| +30% longer operational runtime |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH to 600 TPH nominal throughput of BF Slag (bulk density ~1.6 t/m³).
Power Requirements: Total connected load typically between 150 kW 800 kW depending on configuration; designed for 400V/50Hz or other industrial standards.
Material Specifications: Fabricated from S355JR structural steel; critical wear components in Mn18Cr2 / T500 / AR400+ plate as applicable.
Primary Crusher Options: Jaw Crusher (Feed size up to ~1000mm) or Primary Impact Crusher.
Secondary Crusher Options: Hydraulic Cone Crusher (for harder slags) or Secondary Impact Crusher (for cubical shaping).
Plant Dimensions: Variable based on capacity; typical footprint range from 15m x 25m up to 30m x 50m for full circuit with stockpile conveyors.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dust suppression system compliant with local particulate emission standards.

6. APPLICATION SCENARIOS

Integrated Steel Mill – Slag Valorization

Challenge: A major steel producer was landfilling converter slag at significant cost while purchasing road base material externally.Slag hardness variability caused excessive wear in their existing crushers.
Solution: Implementation of a turnkey Wholesale Slag Crusher Plant featuring a primary impactor with hydraulic adjustment and highwear resistance alloys,followed by a secondary cone crusher for precise control.
Results:The plant now processes over 250 TPH of steel slag.Aggregate meets national road authority specifications,yielding over $1.2M annual revenue while eliminating $250k in landfill fees.Wear part life increased by over 80%.

Construction Materials Contractor – MultiSite Operations

Challenge:A contractor winning bids across multiple demolition sites needed mobile processing but required higher capacityand durability than standard portable rock plants could offer against reinforced concreteand demolition debris containing metallic waste.
Solution:A semimobile Wholesale Slag Crusher Plant skidmounted configurationwith integral magnetic separationand heavyduty prescreening.Deployed across three major urban renewal projects over two years.
Results:The plant achieved consistent throughput of180 TPH on mixed demolition materials.Product quality met strict recycling aggregate specs.Residual metal recovery provided additional scrap revenue.Plant relocation between sites was completed within one week per move,maximizing equipment utilization.

7. COMMERCIAL CONSIDERATIONS

Our Wholesale Slag Crusher Plants are offered in tiered configurations:

Standard Duty Package: For consistent,fairly abrasive slags.Includes core crushing,screening,and basic conveying.Capacities up to150TPH.Idealfor predictable operations focused on capex minimization.
Heavy Duty Package (Recommended):For highly abrasive,variable composition slags.Includes upgraded wear packages,magnetic separatorsat all stages,and automated lubrication.Capacities150–400TPH.Maximizes uptimeand total costofownership value.
Turnkey Premium Package: Includes full electrical control housewith PLC automation,dust suppression/filtration systems,and extended commissioning support.For capacities exceeding400TPHor fully automated facilities requiring minimal operator intervention.

Optional features include telescopic radial stackers,wash systemsfor fines recovery,and remote monitoring telematics.Service packages rangefrom annual inspection plans tooffsite rotor/cap rebuild servicesand guaranteed spare parts availability.Financing options including equipment leasingand projectbased financing solutions are availableto assistwith capital expenditure planning.

8. FAQ

Q1:What levelof preparationis requiredfor incoming slug feed?
A:The plantis designedto handlerunofmill(RoM)slag directfromthe pitor stockpile.Optimal performance assumesfeed sizewithin themaximum dimensionspecifiedfortheprimarycrusheravoidanceof excessive"fines"below30mmloadingthe primary chamberis beneficialbut not mandatorydue toprescreenintegration

Q2:Canyourplantbe integratedintoourexistingmaterialhandlingconveyorsystem?
A Yes Engineeringreviewsofyourcurrentlayoutare standard OurcontrolscanbeinterfacedwithmasterPLCsystems Conveyordischargeheightsandratesareconfiguredtomatchyourupstreamordownstreamequipment

Q3:Whatisthetypicalinstallationandcommissioningtimeline?
A Foraskid mountedorsemi mobileplant onsitecommissioningtakesapproximately twotothreeweeksfollowingfoundationpreparation Fixedplantsrequiremoreextensivecivilworkswithtypicaltimelinesof eighttotwelveweeksfromgroundbreakingtofulloperation

Q4:Doyouprovidewearpartconsumablesguarantees?
A Wearpartperformanceisdirectlylinkedtofeedmaterialcharacteristics Weofferperformancebasedguaranteesontonnageprocessedperwearpartsetbackedbyourmaterialsscience laboratoryanalysisofyourspecificslag sample

Q5:Whattrainingisprovidedforouroperatorsandmaintenancestaff?
A Comprehensiveonsitetrainingisprovidedduringcommissioningcoveringnormaloperation startupshutdowns routine maintenancechecksandsafetyprocedures Detailedmanualsandschematicare suppliedindigitalformat

Q6:Arethereoptionsfordustcontroltomeetstrictenvironmentalregulations?
A Standardplantsincludeintegratedwaterspraysystemsattransferpoints Forstricterrequirements wecanintegratebaghousefilterdustcollectionsystemsorprovideengineeringfortheirretrofit

Q7 Howdoesthepricingmodelworkforoptionalfeaturesorservicepackages?
A Baseplantpricingisclear Equipmentoptionsarepricedàlacarte Servicepackagesaretypicallyannualsubscriptionsbasedonanticipatedoperatinghours Allcommercialtermsaredetailedinproposalpriortoanycommitment