100 TPH Lead-Zinc Ore Crushing Plant in Nigeria

Client Profile

A leading mining operator in Nigeria specializing in lead-zinc extraction, seeking to upgrade their processing capacity to 100 tons per hour while reducing downtime and maintenance costs.

Project Overview

Location: Nigeria
Material: Lead-zinc ore (Mohs hardness: 3.5-4)
Feed Size: ≤500mm
Output Size: 0-25mm (adjustable)
Capacity: 100TPH
Application: Mineral processing plant feed

Challenges

1. Abrasive ore properties causing rapid wear on conventional crushers
2. High humidity environment increasing equipment corrosion risk
3. Unstable power supply requiring energy-efficient solutions
4. Space constraints demanding compact equipment layout

Solution & Equipment Configuration

Liming Heavy Industry designed a two-stage crushing circuit with intelligent automation:

1. Primary Crushing – PE600×900 Jaw Crusher
   • Role: Coarse crushing of raw ore ≤500mm → ≤150mm
   • Advantages:
     • Cast steel frame with reinforced bearings for heavy-load ore
     • “V”-shaped cavity design increases throughput by 15%
     • Dust-proof motor adapts to Nigeria’s humid conditions
2. Secondary Crushing – HST250 Single Cylinder Cone Crusher
   • Role: Fine crushing from ≤150mm → 0-25mm
   • Advantages:
     • Laminated crushing principle reduces wear by 30% vs conventional crushers
     • Hydraulic adjustment system allows quick CSS changes
     • Integrated dust suppression for cleaner operation
3. Auxiliary Equipment:
   • GZD960×3800 Vibrating Feeder – Ensures uniform material flow
   • 3YZS2160 Vibrating Screen – 3-layer classification with 95% screening efficiency
   • Belt Conveyors – Oil-resistant rubber for longevity

Technical Highlights

• Hybrid Power Option: Compatible with diesel generators for power grid instability
• Smart Monitoring: IoT-enabled sensors for real-time wear part diagnostics
• Modular Design: Pre-assembled components reduced installation time by 40%

Results

• Throughput: Consistently achieved 105-110TPH (exceeding target)
• Availability: 98.2% uptime over 12 months
• Energy Efficiency: 35% lower kWh/ton than client’s previous setup
• Maintenance: Wear parts life extended by 20% (HST250 mantle lasts 1,800 hours)

Client Testimonial

“Liming’s PE600×900 jaw crusher and HST250 cone crusher transformed our lead-zinc operation. The automated system cut labor costs by 25%, and the wear-resistant liners reduced our spare parts inventory. This is our most reliable crushing line in Nigeria.”
— Plant Manager, Nigerian Lead-Zinc Mining Co.