1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

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.
Thời gian ngừng hoạt động ngoài kế hoạch: 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, giảm thông lượng tổng thể của nhà máy.
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. TỔNG QUAN SẢN PHẨM

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.

Quy trình hoạt động:
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 (ví dụ., detecting silica, nhôm, 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.

Phạm vi ứng dụng & Hạn chế:
Phạm vi: Lý tưởng cho đá vôi, đá granit, and other aggregate quarries. Used for quality control of feed to primary crushers, grade control, and contaminant detection.
Hạn chế: 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. TÍNH NĂNG CỐT LÕI

RealTime Elemental Analysis | Cơ sở kỹ thuật: Prompt Gamma Neutron Activation Analysis (PGNAA) | Lợi ích hoạt động: Provides minutebyminute data on SiO₂, Al₂₃O₃, CaO, and other critical elements in the bulk flow | Tác động ROI: Enables immediate blending adjustments to reduce product variability by over 70%, minimizing load rejections.

Advanced Contaminant Detection | Cơ sở kỹ thuật: Multienergy sensor calibration for density differentiation | Lợi ích hoạt động: Automatically identifies and flags metallic tramp iron beyond magnet range and lowgrade laterite/clay pockets | Tác động ROI: Prevents costly damage to crusher mantles and liners, reducing related unscheduled downtime by an estimated 40%.

Automated Feedforward Control Integration | Cơ sở kỹ thuật: APIbased communication with plant PLC/DCS systems | Lợi ích hoạt động: Allows crusher automation systems to preadjust settings based on incoming material hardness trends | Tác động ROI: Tối ưu hóa hồ sơ hao mòn và tiêu thụ điện của máy nghiền, cải thiện thông lượng bằng cách 515% depending on feedstock variability.

Unified Process Management Software | Cơ sở kỹ thuật: Cloudenabled platform with historical data analytics | Lợi ích hoạt động: Your plant managers can track quality trends, generate shift reports, and correlate feed data with final product specs from a single dashboard | Tác động ROI: Reduces quality control administrative labor by approximately 20 hours per week and provides data for precise mine planning.

LowMaintenance Robust Design | Cơ sở kỹ thuật: IP66/NEMA 4X rated housing with internal climate control | Lợi ích hoạt động: Built to withstand dust, rung động, độ ẩm,and the ambient temperatures common at quarry sites in Lagos with minimal daily intervention | Tác động ROI: Ensures >95% operational availability with standard quarterly maintenance checks.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Tiêu chuẩn ngành (Manual Sampling) | OnBelt Analytical Solution | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Quality Data Latency | 2 4 giờ (lab turnaround) | < 60 giây (realtime) | ~99% Faster Response |
| Analysis Coverage| < 0.1% tổng số thức ăn (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| Dữ liệu trường hiển thị lên đến 40% reduction in related stoppages |
| Tính nhất quán của sản phẩm (SiO₂ Variance)| High variance due to blind processing| Low variance via continuous monitoring & điều khiển| Demonstrated reduction of spec deviation by >70% |

5. THÔNG SỐ KỸ THUẬT

Đánh giá năng lực: Designed for belt widths from 800 mm đến 2000 mm; handles typical feed rates up to 4000 MT/giờ.
Yêu cầu về nguồn điện: Standard industrial supply: 415V AC ±10%, 50/60 Hz; <15 kVA peak consumption.
Thông số vật liệu: Sensor housing: marinegrade aluminum with stainless steel fittings; Measurement window: wearresistant ceramic alloy.
Kích thước vật lý (Sensor Module): Approximately L2.5m x W2m x H1.8m (varies by belt width).
Phạm vi hoạt động môi trường: Nhiệt độ môi trường xung quanh: 20°C to +55°C; Độ ẩm: Lên đến 95% không ngưng tụ; Compliant with dust and moisture ingress protection standards.

6. KỊCH BẢN ỨNG DỤNG

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.
Giải pháp:
Installation of an onbelt analyzer on the primary feed conveyor monitoring SiO₂ levels in realtime.
Kết quả:
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.
Giải pháp:
Implementation of a system calibrated specifically for alumina detection (clay indicator) ahead of the primary crusher.
Kết quả:
Operators could divert highalumina segments to waste or blending stockpiles. Kiln thermal stability improved significantly,
with recorded fuel savings averaging
3%.

7. CÂN NHẮC THƯƠNG MẠI

Our solutions are configured based on your specific belt width,
loại vật liệu,
and integration depth.

Bậc giá: 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

Tính năng tùy chọn: Supplemental moisture sensors,
extended elemental calibration libraries,
redundant detector arrays
for missioncritical applications,
and satellite data relay
for remote site connectivity

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

Tùy chọn tài chính:
We offer several commercial structures including outright purchase,
hợp đồng cho thuê hoạt động,
and performancelinked financing models where payments can be partially aligned with demonstrated throughput or yield improvements

8 Câu hỏi thường gặp

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