Targeting Sustainable Quarry Operations in Lagos: HighEfficiency Mobile Crushing & Screening Plants

1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Operating a quarry site in Lagos presents distinct challenges that directly impact profitability and operational viability. Gérez-vous:
Escalating Operational Costs: Unpredictable fuel consumption from inefficient, aging equipment and the high expense of transporting raw material to a fixed processing site.
Site Inflexibility & Temps d'arrêt: Significant revenue loss when primary crushers are down for maintenance, or when you need to relocate processing to follow aggregate seams, resulting in days of nonproduction.
Strict Environmental & Community Constraints: Pressure to minimize dust, bruit, and land footprint within Lagos’s rapidly developing periurban areas, alongside the need for rapid site rehabilitation.
Inconsistent Aggregate Quality: Difficulty in meeting precise grading specifications for concrete and road base due to outdated screening technology, leading to product rejection or reduced market value.
High Logistics Complexity: Coordinating multiple machines (excavatrice, primary crusher, screen, convoyeurs) that are not designed as an integrated system, creating bottlenecks and management overhead.

How do you increase yield and reduce costperton while adhering to stricter environmental standards and maintaining operational flexibility?

2. APERÇU DU PRODUIT

Our solution is a trackmounted Mobile Crushing and Screening Plant engineered for sustainable quarrying. This integrated system moves directly to the rock face, eliminating dump trucks between the excavation point and primary crushing.

Flux de travail opérationnel:
1. Direct Face Feeding: An excavator loads blasted rock directly into the mobile plant's hopper at the quarry face.
2. OnSite Size Reduction: The material undergoes primary and often secondary crushing directly on the tracks.
3. Precise Sorting: Integrated highcapacity screens separate crushed material into precisely graded fractions (par ex., 05mm, 510mm, 1020mm).
4. Stockage & Déménagement: Finished aggregates are conveyed to designated stockpiles. The entire plant can be relocated under its own power in under 30 minutes.

Champ d'application: Ideal for mediumtolarge scale granite, calcaire, or laterite quarry operations requiring multiple aggregate products. Suitable for greenfield sites and established pits where moving processing points is necessary.

Limites: Not designed for ultrahard abrasive ores without specific liner configurations. Maximum singlefeed size is determined by plant model; oversize boulders may require prebreaking.

3. CARACTÉRISTIQUES PRINCIPALES

Direct Feed System | Base technique: Optimized hopper geometry and feeder speed control | Avantage opérationnel: Eliminates wheel loader intermediary handling, reducing fuel burn by approximately 18% on loading cycles | Impact sur le retour sur investissement: Direct reduction in fleet fuel costs and loader maintenance.

Hybrid Power Option | Base technique: Entraînement diesel-électrique avec groupe électrogène embarqué; plugin capability | Avantage opérationnel: Enables connection to grid power onsite for stationary periods, cutting fuel consumption by up to 60% during screening/conveying phases | Impact sur le retour sur investissement: Major operational expenditure reduction in areas with stable grid access; lower carbon footprint.

Advanced Dust Suppression | Base technique: Pressurized water spray system with nozzles at all transfer points, combined with sealed conveyor skirts | Avantage opérationnel: Meets Lagos State environmental regulations for particulate emissions without reliance on weatherdependent external systems | Impact sur le retour sur investissement: Avoids regulatory fines and facilitates smoother community relations and permit renewals.

Intelligent Process Control | Base technique: PLCbased system with touchscreen interface monitoring crusher load, pression, et consommation d'énergie | Avantage opérationnel: Operators optimize feed rate automatically to prevent blockages or run empty; realtime diagnostics reduce troubleshooting time by an average of 40% | Impact sur le retour sur investissement: Higher machine availability and increased throughput of saleable product.

Rapid Relocation Capability | Base technique: Trackmounted chassis with hydraulic folding functions for conveyors and screen boxes | Avantage opérationnel: Full plant relocation between faces or sites can be completed within one shift by a minimal crew | Impact sur le retour sur investissement: Maximizes resource extraction from confined leases and drastically reduces downtime during pit advancement.

HighGrade Screening Decks | Base technique: Multilayer vibrating screens with adjustable throw and tensioned rubber deck panels | Avantage opérationnel: Produces consistently graded aggregates that meet Nigerian industrial standards (NSI) for concrete work | Impact sur le retour sur investissement: Commands premium pricing from readymix plants and largescale contractors; minimizes waste of offspec material.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Fixé / SemiMobile Plant) | Our Mobile Crushing & Solution de dépistage | Avantage (% Amélioration) |
| : | : | : | : |
| Fuel Cost per Ton Processed| Haut (Dependent on truck fleet) | Faible (Direct feed + hybrid option) | Jusqu'à 35% réduction |
| Relocation Time Between Faces| 35 jours (Dismantle/Transport/Reassemble) | < 8 heures (Selfpropelled movement) | Sur 90% plus rapide |
| Setup Time on New Site| 12 semaines (Civil works required) | < 24 heures (Minimal ground leveling) | Environ 95% plus rapide |
| System Footprint| Large permanent area required| Compact; follows pit contour| Jusqu'à 60% smaller active area |
| Manpower Required for Operation| 46 personnel across multiple machines| 23 personnel via integrated control cabin| ~40% reduction |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Débit dépendant du modèle à partir de 200 tph to over 450 tph of granite aggregate.
Options du concasseur primaire: Corbeau à mâchoires (for high compressive strength rock) or impact crusher (for higher shape index requirements).
Exigences d'alimentation: Primary drive via Tier IV Final diesel engine (~350 kVA). Optional plugin connection for external electric power (400V/50 Hz).
Spécifications des matériaux clés: Hardox® hopper and wear plates; highstrength steel frame; polyurethane screen deck panels for extended life.
Dimensions physiques (Fonctionnement): Environ. Longueur: 22m, Largeur: 3.5m, Hauteur: 4.2m.
Plage de fonctionnement environnementale: Designed for ambient temperatures of +5°C to +45°C; dust suppression system rated for operation up to 85% humidité relative.

6. SCÉNARIOS D'APPLICATION

Granite Quarry Expansion in Ikorodu Area

Challenge A quarry operator needed to access a new resource block separated by overburden from their existing fixed plant. Trucking raw material was costprohibitive.
Solution Deployment of a mobile crushing & screening plant directly at the new face location.
Results Eliminated a fleet of six dump trucks from the haul cycle. Reduced costperton by an estimated NGN ₦280 while increasing total site output by over NGN ₦22%. The site was fully operational within two days of equipment arrival.

Urban Perimeter Quarry with Noise/Dust Restrictions

Challenge A quarry operating near residential development faced stringent limits on operational hours due to noise complaints.
Solution Implementation of a mobile plant equipped with advanced sounddampening enclosures on crushers/screens and the integrated dust suppression system allowed processing closer to the active face.
Results Demonstrated compliance with regulatory decibel limits at the property boundary through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours , increasing weekly production volume by NGN ₦15%. Community complaints dropped significantly.

7. CONSIDÉRATIONS COMMERCIALES

Equipment is offered in three primary tiers based on capacity:
1. Standard Performance Tier
2.Niveau Haute Capacité
3.Custom Configuration Tier

Optional features include magnetic separators , additional fines washing modules , wireless remote controls ,and upgraded generator sets .

Service packages range from basic scheduled maintenance plans offered comprehensive uptime guarantees including parts kits held locally in our Lagos depot .

Financing options are available including leasetoown structures tailored typically over NGN ₦36NGN ₦60 months as well as partnership models based on production volume .

8.FAQ

What is required infrastructure wise?
The mobile plant requires reasonably stable compacted ground . Minimal civil works are needed beyond basic leveling . Access roads must accommodate standard lowbed trailer dimensions if transport between sites is necessary .

How does particle shape compare fixed cone crushers?
Modern mobile impact crushers equipped advanced rotor designs produce cubical product suitable most concrete applications . For extremely critical shape requirements jawcrusher based mobile units are recommended .

Quel délai de livraison typique mise en service?
From order confirmation delivery typically occurs within NGN ₦14NGN ₦18 weeks . Commissioning supervised our engineers takes approximately NGN ₦5 working days including operator training .

Are spare parts readily available Nigeria?
Yes we stock critical wear parts consumables our dedicated Lagos warehouse ensuring nextbusinessday availability most common items reducing potential downtime .

Can this equipment process laterite effectively?
Yes but configuration recommendations differ . For laterite applications we recommend specific screening media feed arrangements prevent clogging ensure optimal efficiency .