1. PAINPOINT DRIVEN OPENING

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. The solution lies not just in equipment, 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. PRODUCT OVERVIEW

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

Operational Workflow:
1. Primary Feeding & PreScreening: Dump trucks deposit ROQ material into a vibrating grizzly feeder (VGF), which removes natural fines and bypasses subsize material.
2. Primary Crushing: Oversize material is conveyed to a robust primary jaw crusher for initial compression breaking.
3. Secondary Crushing & Screening: Crushed output is routed to a secondary cone crusher for further reduction, then to a multideck vibrating screen for precise classification.
4. Stockpiling: Sized aggregates (e.g., ¾”, ½”, dust) are conveyed to designated stockpiles for direct loading or further processing.

Application Scope & Limitations:
Scope: Ideal for mediumtolarge scale quarry operations targeting consistent production of construction aggregates (granite, limestone). Suitable for integration with asphalt or concrete batching plants onsite.
Limitations: Requires stable, 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. CORE FEATURES

HeavyDuty Vibrating Grizzly Feeder (VGF) | Technical Basis: Highinertia vibratory mechanism with adjustable grizzly bars | Operational Benefit: Removes fines prior to crushing, reduces crusher load and wear, prevents hopper bridging | ROI Impact: Extends crusher liner life by up to 30%, reduces fuel consumption by optimizing crusher workload

Primary Jaw Crusher with Wedge System | Technical Basis: Manganese steel jaws with hydraulic adjustment and toggle tensioning | Operational Benefit: Handles large, irregular slabs of Lagos granite without clogging; allows quick CSS adjustment for product size changes | ROI Impact: Minimizes downtime for size changes; high reduction ratio decreases load on downstream circuits

Centralized Greasing & PLC Control System | Technical Basis: Automated lubrication points linked to a programmable logic controller with fault diagnostics | Operational Benefit: Ensures critical bearings receive timely lubrication in dusty conditions; provides operators with realtime monitoring of plant functions | ROI Impact: Prevents catastrophic bearing failures; reduces manual maintenance time by an estimated 15 hours per week

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

SoundAttenuated Enclosures & Dust Suppression | Technical Basis: Canopy panels with acoustic insulation and strategically placed water spray nozzles | Operational Benefit: Significantly reduces operational noise and dust emissions at transfer points | ROI Impact: Facilitates compliance with local environmental guidelines, minimizing risk of operational delays due to complaints.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Mobile Units) | Stationary Quarry Plant Solution | Advantage (% improvement) |
| : | : | : | : |
| Tonnage Processed per Litre of Fuel| ~5060 tonnes/litre (multiple unit movements) | ~90110 tonnes/litre (conveyorbased transfer) | +80% efficiency |
| Product Consistency (Gradation)| Varies due to frequent relocation/ setup changes| Consistent ±5% tolerance on spec aggregates| +70% consistency |
| Liner Wear Life in Primary Stage| Subject to more direct impact from unscreened fines| Extended life due to effective grizzly prescreening| +30% longevity |
| Setup/Relocation Time| 12 days per major move| 710 days for initial installation (semipermanent)| 75% mobility but +95% stability |

5. TECHNICAL SPECIFICATIONS

Design Capacity: 150 350 tonnes per hour (configurable based on crusher model).
Primary Power Requirement: 200 400 kVA grid connection or equivalent diesel generator set.
Material Specifications: Fabricated from S355JR structural steel; abrasionresistant steel liners at highwear points; Grade III manganese steel crusher jaws.
Key Physical Dimensions: Typical footprint of 40m (L) x 18m (W). Feed hopper height: 4.5m.
Environmental Operating Range: Designed for ambient temperatures of 20°C to 45°C; humidity up to 90%; dust protection rating of IP55 on electrical components.

6. APPLICATION SCENARIOS

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

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

7. COMMERCIAL CONSIDERATIONS

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

Optional Features: Dust encapsulation cabins, automated metal detection/removal systems, advanced rock breaker systems at feed hopper, remote monitoring telematics.

Service Packages: Tiered annual maintenance contracts are available covering scheduled inspections, liner changeouts, and priority technical support.

Financing Options: 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. FAQ

Q1: Is this plant compatible with our existing excavators and haul trucks?
Yes. The receiving hopper and feeder are engineered to accommodate standard quarry haul truck discharge heights and volumes used in Lagos operations.

Q2: 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.

Q3: 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.

Q4: 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