1. PAINPOINT DRIVEN OPENING

Managing consistent, highquality aggregate supply from quarry sites in Lagos is a persistent operational bottleneck. Are you facing these critical challenges?

Variable Feedstock Quality: Inconsistent rock hardness and contamination from laterite or clay directly impact crusher efficiency and final product specification, leading to rejected loads and contract penalties.
Unplanned Downtime: Equipment failure at the primary crushing stage due to uncrushable materials or excessive wear causes cascading delays, idling your entire processing line and haul fleet.
Inaccurate Yield Forecasting: Without realtime data on material hardness and size distribution, planning optimal crusher settings and maintenance windows is guesswork, reducing overall plant throughput.
Quality Control Lag Times: Waiting for lab results from sampled stockpiles means potentially shipping substandard material or failing to blend correctly, damaging your reputation with key clients in Lagos’s construction sector.

How can you gain realtime insight into your feed material to proactively protect your crushers, guarantee product specs, and optimize your entire production chain?

2. PRODUCT OVERVIEW

The solution is an integrated onbelt analytical system for primary feed control. This industrial equipment provides continuous, noncontact elemental and material analysis of the raw feed on your primary conveyor.

Operational Workflow:
1. The system’s sensor is mounted above the conveyor carrying runofquarry material to the primary crusher.
2. As material passes underneath, it performs instantaneous elemental analysis (e.g., detecting silica, alumina, calcium) and assesses material characteristics.
3. Data is transmitted to the plant’s control room software, which displays realtime composition and creates a compositional map of the feedstock.
4. Alerts can be configured to warn operators of harmful contaminants or significant grade changes.
5. This intelligence allows for proactive adjustments—such as minor feeder speed changes or initiating diversion—to protect downstream equipment and stabilize product quality.

Application Scope & Limitations:
Scope: Ideal for limestone, granite, and other aggregate quarries. Used for quality control of feed to primary crushers, grade control, and contaminant detection.
Limitations: Requires consistent belt loading for optimal accuracy. Not a replacement for precise laboratory chemical analysis for final product certification but eliminates the delay for process control.

3. CORE FEATURES

RealTime Elemental Analysis | Technical Basis: Prompt Gamma Neutron Activation Analysis (PGNAA) | Operational Benefit: Provides minutebyminute data on SiO₂, Al₂₃O₃, CaO, and other critical elements in the bulk flow | ROI Impact: Enables immediate blending adjustments to reduce product variability by over 70%, minimizing load rejections.

Advanced Contaminant Detection | Technical Basis: Multienergy sensor calibration for density differentiation | Operational Benefit: Automatically identifies and flags metallic tramp iron beyond magnet range and lowgrade laterite/clay pockets | ROI Impact: Prevents costly damage to crusher mantles and liners, reducing related unscheduled downtime by an estimated 40%.

Automated Feedforward Control Integration | Technical Basis: APIbased communication with plant PLC/DCS systems | Operational Benefit: Allows crusher automation systems to preadjust settings based on incoming material hardness trends | ROI Impact: Optimizes crusher power draw and wear profile, improving throughput by 515% depending on feedstock variability.

Unified Process Management Software | Technical Basis: Cloudenabled platform with historical data analytics | Operational Benefit: Your plant managers can track quality trends, generate shift reports, and correlate feed data with final product specs from a single dashboard | ROI Impact: Reduces quality control administrative labor by approximately 20 hours per week and provides data for precise mine planning.

LowMaintenance Robust Design | Technical Basis: IP66/NEMA 4X rated housing with internal climate control | Operational Benefit: Built to withstand dust, vibration, humidity,and the ambient temperatures common at quarry sites in Lagos with minimal daily intervention | ROI Impact: Ensures >95% operational availability with standard quarterly maintenance checks.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Manual Sampling) | OnBelt Analytical Solution | Advantage (% Improvement) |
| : | : | : | : |
| Quality Data Latency | 2 4 hours (lab turnaround) | < 60 seconds (realtime) | ~99% Faster Response |
| Analysis Coverage| < 0.1% of total feed (spot samples) | 100% of conveyed material (fullstream) | Representative Data Improvement |
| Crusher Downtime from Contaminants| Reactive shutdown after damage occurs / metal detection only| Proactive alert before entry / detects nonmetallic lowgrade zones| Field data shows up to 40% reduction in related stoppages |
| Product Consistency (SiO₂ Variance)| High variance due to blind processing| Low variance via continuous monitoring & control| Demonstrated reduction of spec deviation by >70% |

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Designed for belt widths from 800 mm to 2000 mm; handles typical feed rates up to 4000 MT/hr.
Power Requirements: Standard industrial supply: 415V AC ±10%, 50/60 Hz; <15 kVA peak consumption.
Material Specifications: Sensor housing: marinegrade aluminum with stainless steel fittings; Measurement window: wearresistant ceramic alloy.
Physical Dimensions (Sensor Module): Approximately L2.5m x W2m x H1.8m (varies by belt width).
Environmental Operating Range: Ambient Temperature: 20°C to +55°C; Humidity: Up to 95% noncondensing; Compliant with dust and moisture ingress protection standards.

6. APPLICATION SCENARIOS

Granite Aggregate Production, Lekki Corridor Challenge:

A major quarry supplying concrete plants faced high rejection rates of crushed stone due to inconsistent crystalline silica content impacting bitumen adhesion tests.
Solution:
Installation of an onbelt analyzer on the primary feed conveyor monitoring SiO₂ levels in realtime.
Results:
Realtime data enabled controlled blending of high and lowsilica faces. Final product consistency met stringent DOT specifications continuously, reducing rejected loads by over 85% within three months.

Limestone Quarry for Cement Clinker Feed Challenge:

Variable clay content in limestone feed was causing unstable kiln operation and increased specific fuel consumption at a linked cement plant.
Solution:
Implementation of a system calibrated specifically for alumina detection (clay indicator) ahead of the primary crusher.
Results:
Operators could divert highalumina segments to waste or blending stockpiles. Kiln thermal stability improved significantly,
with recorded fuel savings averaging
3%.

7. COMMERCIAL CONSIDERATIONS

Our solutions are configured based on your specific belt width,
material type,
and integration depth.

Pricing Tiers: Entrylevel systems provide core realtime analysis
and basic reporting
for singleplant operations
Premium tiers include advanced predictive analytics,
multiplant data aggregation,
and automated control interfaces

Optional Features: Supplemental moisture sensors,
extended elemental calibration libraries,
redundant detector arrays
for missioncritical applications,
and satellite data relay
for remote site connectivity

Service Packages:
Comprehensive plans include scheduled preventative maintenance,
remote diagnostics,
annual calibration verification,
and guaranteed response times
for technical support

Financing Options:
We offer several commercial structures including outright purchase,
operational lease agreements,
and performancelinked financing models where payments can be partially aligned with demonstrated throughput or yield improvements

8 FAQ

What integration is required with my existing plant PLC?
The system operates as a standalone unit but communicates via standard industrial protocols Modbus TCP/IP OPC UA Minimal integration is needed for data viewing full integration for automated control requires coordination with your controls engineer

How does the system handle the heavy dust conditions prevalent at quarry sites in Lagos?
The analyzer uses a sealed measurement chamber with internal positive air pressure
and proprietary selfcleasing mechanisms Field installations demonstrate reliable operation in highdust environments exceeding typical quarry conditions

What is the typical accuracy compared to lab analysis?
For process control purposes correlation with laboratory results typically shows an R value exceeding For absolute certification lab analysis remains the reference method but this system eliminates the delay making it ideal for realtime operational decisions

What training do our operators require?
We provide onsite commissioning training covering normal operation basic troubleshooting
and data interpretation Most operators become proficient within shifts Advanced training on datal analytics is available

What are the safety provisions regarding the analyzer's operation?
The system incorporates multiple layers of safety including locked shielding radiation monitoring devices automatic shutoff mechanisms if housing is breached It complies fully with all relevant international nuclear safety regulations for industrial equipment