1. PEMBUKAAN PAINPOINT DRIVEN

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. Penyelesaiannya bukan hanya terletak pada peralatan, 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. GAMBARAN KESELURUHAN PRODUK

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, batu kapur, and laterite, transforming runofquarry (ROQ) rock into specified aggregate fractions.

Aliran Kerja Operasi:
1. Pemakanan Utama & PraSkrining: Dump trucks deposit ROQ material into a vibrating grizzly feeder (VGFF VGF), yang menghilangkan denda semula jadi dan memintas bahan subsaiz.
2. Penghancuran utama: Oversize material is conveyed to a robust primary jaw crusher for initial compression breaking.
3. Menghancurkan sekunder & Pemeriksaan: Crushed output is routed to a secondary cone crusher for further reduction, then to a multideck vibrating screen for precise classification.
4. Stok: Sized aggregates (mis., ¾”, ½”, habuk) are conveyed to designated stockpiles for direct loading or further processing.

Skop Permohonan & Batasan:
Skop: Ideal for mediumtolarge scale quarry operations targeting consistent production of construction aggregates (granit, batu kapur). Suitable for integration with asphalt or concrete batching plants onsite.
Batasan: Memerlukan stabil, 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. CIRI TERAS

Penyumpan Grizzly Bergetar Tugas Berat (VGFF VGF) | Asas Teknikal: Mekanisme getaran highinersia dengan bar grizzly boleh laras | Faedah Operasi: Menghilangkan denda sebelum dihancurkan, mengurangkan beban penghancur dan haus, prevents hopper bridging | Kesan ROI: Memanjangkan hayat pelapik penghancur sehingga 30%, reduces fuel consumption by optimizing crusher workload

Penghancur Rahang Utama dengan Sistem Baji | Asas Teknikal: Manganese steel jaws with hydraulic adjustment and toggle tensioning | Faedah Operasi: Mengendalikan besar, irregular slabs of Lagos granite without clogging; allows quick CSS adjustment for product size changes | Kesan ROI: Meminimumkan masa henti untuk perubahan saiz; high reduction ratio decreases load on downstream circuits

Centralized Greasing & Sistem Kawalan PLC | Asas Teknikal: Automated lubrication points linked to a programmable logic controller with fault diagnostics | Faedah Operasi: Ensures critical bearings receive timely lubrication in dusty conditions; provides operators with realtime monitoring of plant functions | Kesan ROI: Menghalang kegagalan galas bencana; reduces manual maintenance time by an estimated 15 jam setiap minggu

Modular Conveyor System with Chevron Belting | Asas Teknikal: Interlocked conveyor modules with highgrip belting for steep inclines | Faedah Operasi: Efficiently moves material between stages with minimal spillage, even in wet conditions common during Lagos rainy seasons | Kesan ROI: Lowers rehandling costs and preserves site cleanliness; belt design reduces rollback, improving throughput

SoundAttenuated Enclosures & Penindasan Debu | Asas Teknikal: Canopy panels with acoustic insulation and strategically placed water spray nozzles | Faedah Operasi: Significantly reduces operational noise and dust emissions at transfer points | Kesan ROI: Facilitates compliance with local environmental guidelines, minimizing risk of operational delays due to complaints.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Unit Mudah Alih) | Stationary Quarry Plant Solution | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Tonnage Processed per Litre of Fuel| ~5060 tonnes/litre (multiple unit movements) | ~90110 tonnes/litre (conveyorbased transfer) | +80% kecekapan |
| Konsistensi Produk (Penggredan)| Varies due to frequent relocation/ setup changes| Consistent ±5% tolerance on spec aggregates| +70% konsisten |
| Liner Wear Life in Primary Stage| Subject to more direct impact from unscreened fines| Extended life due to effective grizzly prescreening| +30% panjang umur |
| Masa Persediaan/Penempatan Semula| 12 days per major move| 710 days for initial installation (semipermanent)| 75% mobility but +95% kestabilan |

5. SPESIFIKASI TEKNIKAL

Kapasiti Reka Bentuk: 150 350 tan sejam (configurable based on crusher model).
Keperluan Kuasa Utama: 200 400 kVA grid connection or equivalent diesel generator set.
Spesifikasi Bahan: Dibuat daripada keluli struktur S355JR; abrasionresistant steel liners at highwear points; Grade III manganese steel crusher jaws.
Dimensi Fizikal Utama: Typical footprint of 40m (L) x 18m (W). Feed hopper height: 4.5m.
Julat Operasi Persekitaran: Direka untuk suhu ambien 20°C hingga 45°C; kelembapan sehingga 90%; dust protection rating of IP55 on electrical components.

6. SENARIO APLIKASI

Granite Aggregate Production for Lagos Road Projects | Cabaran: A quarry supplying base materials for a major highway experienced trucking bottlenecks and inconsistent product gradation using standalone mobile crushers, leading to rejected loads.| Penyelesaian: Implementation of a fixed primary quarry plant near the extraction face with integrated screening.| Keputusan: 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 bulan.

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

7. PERTIMBANGAN KOMERSIL

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

Ciri Pilihan: Kabin enkapsulasi habuk, automated metal detection/removal systems, advanced rock breaker systems at feed hopper, telematik pemantauan jarak jauh.

Pakej Perkhidmatan: Kontrak penyelenggaraan tahunan berperingkat tersedia meliputi pemeriksaan berjadual, pertukaran pelapik, dan sokongan teknikal keutamaan.

Pilihan Pembiayaan: 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. Soalan Lazim

S1: Is this plant compatible with our existing excavators and haul trucks?
ya. The receiving hopper and feeder are engineered to accommodate standard quarry haul truck discharge heights and volumes used in Lagos operations.

S2: 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.

S3: 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.

S4: 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.

S5: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