Buy Cheap, Pay Twice – Cost Comparison of XRF vs. OES in Slag Analysis

When it comes to purchasing new analytical instruments in a steel plant, the lowest purchase price often hides the true operational costs. In slag analysis, the total cost of ownership is not defined by equipment price alone — labor time, maintenance, automation, and sample throughput can have a much larger financial impact over time.

Disclaimer: Every steel plant is unique. Factors such as plant layout, analytical needs of the meltshop, range of analytical methods, internal engineering, purchasing strategy, or direct imports can strongly influence cost structures. The figures below are therefore guidelines only. For individual consultation, please contact us or your local QuantoLux partner.

Typical Instrumentation and Investment Costs in Slag Analysis

Depending on analytical requirements, there are several RFA and OES options available:

• XRF handheld analyzers: €30,000–60,000

• XRF benchtop instruments: €50,000–100,000

• Full-scale laboratory XRF systems: €100,000–200,000

• Sample preparation equipment (mandatory for XRF): crushers, mills, balances, mixers, presses: €20,000–100,
  eSemi-automated mill and press units: €200,000–300,000

• Automation and pneumatic tube systems: from €100,000

• At-line OES slag analyzers: €180,000–250,000 + crusher (~€10,000)

Cost per Analysis – the Real Decision Factor

The purchase price alone rarely reflects the true cost per sample. The following comparison highlights how analysis time and workflow design affect total costs:

Manual Sample Preparation + RFA Example

• Analyzer price: €120,000

• Analysis time: 10–15 minutes per sample

• Labor cost: >€10 per analysis (at €49/hour)

Semi- or Fully Automated RFA Systems

• Significantly reduced manual work

• Higher investment and maintenance expenses

Laser OES

• Direct analysis on crushed slag

• Minimal sample preparation

• Up to 90 % reduction in labor cost

• Can be performed as an additional task by control room or furnace operators

Example Calculation – 30 Samples/Day, €49/hour

Conclusion: Even at moderate throughput (30 samples/day), clear cost differences emerge. With higher sample volumes, analysis time becomes the dominant cost factor.
Request the full .xls: alexander.schlemminger@quantolux.de

Excel Cost Calculator – Make Your Own Comparison

As mentioned in the disclaimer, each steel plant is unique.
To allow users to perform their own cost calculations, we’ve created a simple and flexible Excel calculator.

Purpose: To reveal the true costs of slag analysis based on your individual parameters.
The table is easy to use and can be extended or customized.

Adjustable input parameters include:

• Number of samples per day

• Hourly labor rate

• Instrument cost and lifetime

• Concumables

• Sample preparation and analysis time

Request the full .xls: alexander.schlemminger@quantolux.de

With this tool, you can immediately see how investment, maintenance, and labor contribute to your total annual costs — and where optimization potential lies.

Summary – RFA vs. OES Cost Perspective

• Shorter analysis and preparation times can significantly reduce total analysis cost

• RFA solutions remain ideal for certain applications, particularly where analytical diversity or established lab workflows are required

• Cost comparisons without evaluating analysis time overlook key operational factors

• Considering labor effort, maintenance, and depreciation is essential for a realistic cost model

Our tip: Don’t just look at the purchase price — evaluate the total cost of ownership. By including labor, maintenance, and utilization, you gain a clear picture of the real economic impact of your slag analysis solution.