1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Managing a quarry site in Lagos presents distinct operational hurdles that directly impact profitability and project timelines. Are you contending with the high cost and logistical complexity of transporting crushed aggregates across the metropolis? Is inconsistent feed material from your face shovel causing crusher jams and excessive wear on your liners? Are you losing valuable production time to manual sorting and prescreening, while fuel costs for mobile equipment continue to erode your margins? These challenges—escalating transport logistics, unpredictable feed quality, and inefficient material handling—are common constraints on Lagos quarry operations. La solution ne réside pas seulement dans l’équipement, but in strategic site planning and optimized primary processing. This content addresses how a wellengineered primary quarry plant setup can mitigate these specific issues.

2. APERÇU DU PRODUIT

A stationary primary quarry crushing and screening plant is an integrated processing system designed for the initial size reduction and classification of blasted rock at the extraction site. For operations in Lagos, this setup is engineered to handle local granite, calcaire, et latérite, transforming runofquarry (ROQ) rock into specified aggregate fractions.

Flux de travail opérationnel:
1. Alimentation primaire & Présélection: Dump trucks deposit ROQ material into a vibrating grizzly feeder (VGFF VGF), qui élimine les fines naturelles et contourne les matériaux de petite taille.
2. Concassage primaire: Oversize material is conveyed to a robust primary jaw crusher for initial compression breaking.
3. Concassage secondaire & Dépistage: Crushed output is routed to a secondary cone crusher for further reduction, then to a multideck vibrating screen for precise classification.
4. Stockage: Sized aggregates (par ex., ¾", ½", poussière) are conveyed to designated stockpiles for direct loading or further processing.

Champ d'application & Limites:
Portée: Ideal for mediumtolarge scale quarry operations targeting consistent production of construction aggregates (granit, calcaire). Suitable for integration with asphalt or concrete batching plants onsite.
Limites: Nécessite une stabilité, prepared ground for installation. Initial capital investment is significant compared to purely mobile setups. Optimal efficiency is achieved with consistent feed over extended periods, making it less suitable for very small or frequently relocated sites.

3. CARACTÉRISTIQUES PRINCIPALES

Mangeoire vibrante robuste pour grizzlis (VGFF VGF) | Base technique: Mécanisme vibrant à haute inertie avec barres grizzly réglables | Avantage opérationnel: Élimine les fines avant le broyage, réduit la charge et l'usure du concasseur, prevents hopper bridging | Impact sur le retour sur investissement: Prolonge la durée de vie du revêtement du concasseur jusqu'à 30%, reduces fuel consumption by optimizing crusher workload

Primary Jaw Crusher with Wedge System | Base technique: Manganese steel jaws with hydraulic adjustment and toggle tensioning | Avantage opérationnel: Poignées grandes, irregular slabs of Lagos granite without clogging; allows quick CSS adjustment for product size changes | Impact sur le retour sur investissement: Minimise les temps d'arrêt pour les changements de taille; high reduction ratio decreases load on downstream circuits

Graissage centralisé & Système de contrôle PLC | Base technique: Automated lubrication points linked to a programmable logic controller with fault diagnostics | Avantage opérationnel: Ensures critical bearings receive timely lubrication in dusty conditions; provides operators with realtime monitoring of plant functions | Impact sur le retour sur investissement: Empêche les défaillances catastrophiques des roulements; reduces manual maintenance time by an estimated 15 heures par semaine

Modular Conveyor System with Chevron Belting | Base technique: Interlocked conveyor modules with highgrip belting for steep inclines | Avantage opérationnel: Efficiently moves material between stages with minimal spillage, even in wet conditions common during Lagos rainy seasons | Impact sur le retour sur investissement: Lowers rehandling costs and preserves site cleanliness; belt design reduces rollback, improving throughput

SoundAttenuated Enclosures & Suppression de la poussière | Base technique: Canopy panels with acoustic insulation and strategically placed water spray nozzles | Avantage opérationnel: Significantly reduces operational noise and dust emissions at transfer points | Impact sur le retour sur investissement: Facilitates compliance with local environmental guidelines, minimizing risk of operational delays due to complaints.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Unités mobiles) | Stationary Quarry Plant Solution | Avantage (% amélioration) |
| : | : | : | : |
| Tonnage Processed per Litre of Fuel| ~5060 tonnes/litre (multiple unit movements) | ~90110 tonnes/litre (conveyorbased transfer) | +80% efficacité |
| Cohérence du produit (Gradation)| Varies due to frequent relocation/ setup changes| Consistent ±5% tolerance on spec aggregates| +70% cohérence |
| Liner Wear Life in Primary Stage| Subject to more direct impact from unscreened fines| Extended life due to effective grizzly prescreening| +30% longévité |
| Temps d'installation/de déménagement| 12 days per major move| 710 days for initial installation (semipermanent)| 75% mobility but +95% stabilité |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de conception: 150 350 tonnes par heure (configurable based on crusher model).
Exigence d'alimentation primaire: 200 400 kVA grid connection or equivalent diesel generator set.
Spécifications matérielles: Fabriqué à partir d'acier de construction S355JR; abrasionresistant steel liners at highwear points; Grade III manganese steel crusher jaws.
Dimensions physiques clés: Typical footprint of 40m (L) x 18m (W). Feed hopper height: 4.5m.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à 45°C; humidité jusqu'à 90%; indice de protection contre la poussière IP55 sur les composants électriques.

6. SCÉNARIOS D'APPLICATION

Granite Aggregate Production for Lagos Road Projects | Défi: A quarry supplying base materials for a major highway experienced trucking bottlenecks and inconsistent product gradation using standalone mobile crushers, leading to rejected loads.| Solution: Implementation of a fixed primary quarry plant near the extraction face with integrated screening.| Résultats: Onsite stockpiling eliminated truck queues at the face. Consistent product quality reduced rejection rate from ~12% to under 2%. Projected payback period from transport savings alone was under 24 mois.

Integrated Concrete Block Making Operation | Défi: A block manufacturer sourcing crushed stone faced volatile pricing and quality from thirdparty suppliers, disrupting batching formulas.| Solution: Establishment of a captive quarry using a compact primary jawandscreen plant dedicated to producing specific aggregate sizes for block mixes.| Résultats: Secured control over raw material cost and supply continuity. A atteint un 25% reduction in aggregate input costs while improving block compressive strength consistency by 15%.

7. CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification: Solutions are typically configured projectbyproject.
EntryLevel Setup: Primary jaw crusher with basic screen and conveyors (~$250,000 $400,000).
Usine de production standard: As described in overview with secondary crusher (~$500,000 $850,000).
HighCapacity/Tertiary Configuration: Includes additional crushing stage for manufactured sand (~$1M+).

Fonctionnalités facultatives: Dust encapsulation cabins, automated metal detection/removal systems, advanced rock breaker systems at feed hopper, télématique de surveillance à distance.

Forfaits de services: Tiered annual maintenance contracts are available covering scheduled inspections, changements de doublure, et un support technique prioritaire.

Options de financement: Equipment leasing structures through partnered financial institutions or milestonebased project financing can be explored to align capital expenditure with cash flow from project contracts.

8. FAQ

T1: Is this plant compatible with our existing excavators and haul trucks?
Oui. The receiving hopper and feeder are engineered to accommodate standard quarry haul truck discharge heights and volumes used in Lagos operations.

T2: What is the expected impact on our daily operational manpower?
Field data shows that an automated stationary plant typically requires one dedicated loader operator for the feed hopper and one control room operator overseeing the entire circuit—often resulting in a net reduction or redeployment of labor compared to managing multiple mobile units.

T3: How do we handle power instability common in some areas?
Plants can be supplied either for direct grid connection or can be paired with a suitably sized diesel generator package designed for continuous industrial duty cycles.

T4: What are the commercial terms regarding delivery and commissioning?
Supply terms are typically CIF Apapa Port Incoterms® 2020. Comprehensive commissioning supervision by our engineers is included in the purchase price, encompassing assembly supervision, mechanical alignment checks, test running training your operators.

Q5:What is the lead time from order placement until operational commissioning at our Lagos site?
Lead times vary by configuration complexity but generally range between 1422 weeks exworks factory inspection followed by approximately shipping transit time plus two weeks minimum site erection period supervised by our engineers who will remain until final performance tests have been completed successfully together