1. ABERTURA ACIONADA POR PAINPOINT

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. A solução não está apenas nos equipamentos, 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. VISÃO GERAL DO PRODUTO

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, calcário, e laterita, transforming runofquarry (ROQ) rock into specified aggregate fractions.

Fluxo de Trabalho Operacional:
1. Alimentação Primária & Pré-triagem: Dump trucks deposit ROQ material into a vibrating grizzly feeder (VGF VGF), que remove finos naturais e ignora material subdimensionado.
2. Britagem Primária: Oversize material is conveyed to a robust primary jaw crusher for initial compression breaking.
3. Britagem Secundária & Triagem: Crushed output is routed to a secondary cone crusher for further reduction, then to a multideck vibrating screen for precise classification.
4. Estoque: Sized aggregates (por exemplo, ¾”, ½”, pó) are conveyed to designated stockpiles for direct loading or further processing.

Escopo de aplicação & Limitações:
Escopo: Ideal for mediumtolarge scale quarry operations targeting consistent production of construction aggregates (granito, calcário). Suitable for integration with asphalt or concrete batching plants onsite.
Limitações: Requer estável, terreno preparado para instalação. 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. RECURSOS PRINCIPAIS

Alimentador Grizzly Vibratório para Serviço Pesado (VGF VGF) | Base Técnica: Mecanismo vibratório de alta inércia com barras grizzly ajustáveis | Benefício Operacional: Remove finos antes da britagem, reduz a carga e o desgaste do britador, prevents hopper bridging | Impacto do ROI: Prolonga a vida útil do revestimento do britador em até 30%, reduces fuel consumption by optimizing crusher workload

Primary Jaw Crusher with Wedge System | Base Técnica: Manganese steel jaws with hydraulic adjustment and toggle tensioning | Benefício Operacional: Alças grandes, irregular slabs of Lagos granite without clogging; allows quick CSS adjustment for product size changes | Impacto do ROI: Minimizes downtime for size changes; high reduction ratio decreases load on downstream circuits

Lubrificação Centralizada & Sistema de controle CLP | Base Técnica: Automated lubrication points linked to a programmable logic controller with fault diagnostics | Benefício Operacional: Ensures critical bearings receive timely lubrication in dusty conditions; provides operators with realtime monitoring of plant functions | Impacto do ROI: Evita falhas catastróficas nos rolamentos; reduces manual maintenance time by an estimated 15 horas por semana

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

SoundAttenuated Enclosures & Supressão de poeira | Base Técnica: Canopy panels with acoustic insulation and strategically placed water spray nozzles | Benefício Operacional: Significantly reduces operational noise and dust emissions at transfer points | Impacto do ROI: Facilitates compliance with local environmental guidelines, minimizing risk of operational delays due to complaints.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Unidades Móveis) | Stationary Quarry Plant Solution | Vantagem (% melhoria) |
| : | : | : | : |
| Tonnage Processed per Litre of Fuel| ~5060 tonnes/litre (multiple unit movements) | ~90110 tonnes/litre (conveyorbased transfer) | +80% eficiência |
| Consistência do Produto (Gradação)| Varies due to frequent relocation/ setup changes| Consistent ±5% tolerance on spec aggregates| +70% consistência |
| Liner Wear Life in Primary Stage| Subject to more direct impact from unscreened fines| Extended life due to effective grizzly prescreening| +30% longevidade |
| Tempo de configuração/relocação| 12 days per major move| 710 days for initial installation (semipermanent)| 75% mobility but +95% estabilidade |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade de projeto: 150 350 toneladas por hora (configurable based on crusher model).
Requisito de energia primária: 200 400 kVA grid connection or equivalent diesel generator set.
Especificações de materiais: Fabricado em aço estrutural S355JR; abrasionresistant steel liners at highwear points; Grade III manganese steel crusher jaws.
Principais dimensões físicas: Typical footprint of 40m (eu) x 18m (C). Feed hopper height: 4.5eu.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a 45°C; umidade até 90%; classificação de proteção contra poeira IP55 em componentes elétricos.

6. CENÁRIOS DE APLICAÇÃO

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

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

7. CONSIDERAÇÕES COMERCIAIS

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

Recursos opcionais: Cabines de encapsulamento de poeira, automated metal detection/removal systems, advanced rock breaker systems at feed hopper, telemática de monitoramento remoto.

Pacotes de serviços: Contratos de manutenção anuais escalonados estão disponíveis cobrindo inspeções programadas, trocas de revestimento, e suporte técnico prioritário.

Opções de financiamento: 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. Perguntas frequentes

1º trimestre: Is this plant compatible with our existing excavators and haul trucks?
Sim. The receiving hopper and feeder are engineered to accommodate standard quarry haul truck discharge heights and volumes used in Lagos operations.

2º trimestre: 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.

3º trimestre: 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.

4º trimestre: 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