1. PAINPOINT DRIVEN OPENING

Managing a quarry site in Lagos presents a distinct set of operational and financial pressures. Are you contending with the high cost and logistical complexity of transporting crushed aggregates across the metroplex? Is inconsistent feed material from your primary face causing bottlenecks in your crushing circuit, leading to suboptimal yield? Are you facing excessive downtime due to equipment not engineered for the region's abrasive granite deposits and humid climate? Each hour of unplanned stoppage directly impacts your bottom line, while inconsistent product gradation risks client contracts and project specifications. The core question for commercial buyers and plant managers is this: how do you establish a reliable, highyield secondary processing node to maximize material value onsite and secure your supply chain?

2. PRODUCT OVERVIEW

This content outlines the strategic implementation of a stationary secondary and tertiary crushing and screening plant, specifically configured for quarry sites in Lagos. This turnkey solution is designed to process primary crushed granite into precisely graded aggregates (e.g., ¾”, ½”, ¾1½”, stone dust) for direct market supply.

Operational Workflow:
1. Feed Reception: Primary crushed rock (typically 8” from jaw crusher output) is conveyed to a largecapacity surge hopper, regulating feed to the secondary stage.
2. Secondary Crushing & Sizing: A robust cone crusher performs intermediate reduction. A primary screen then separates material into onspec product streams and oversize for tertiary processing.
3. Tertiary Crushing & Final Sizing: Oversize is routed to a tertiary impact crusher or fine cone crusher for final shaping and size reduction, then recirculated to screening decks.
4. Product Stockpiling: Correctly sized aggregates are conveyed to designated stockpiles via radial stackers, minimizing rehandling.

Application Scope & Limitations:
Scope: Ideal for established quarries with consistent primary crushing output, aiming to produce multiple aggregate specifications concurrently for readymix concrete, asphalt production, and construction fill.
Limitations: Not a replacement for primary blasting and initial jaw/gyratory crushing. Requires adequate space for plant layout and conveyor systems. Site preparation including a stable, drained platform is essential.

3. CORE FEATURES

HeavyDuty Cone Crusher | Technical Basis: Hydraulic adjustment and overload protection system | Operational Benefit: Enables realtime adjustment of CSS (Closed Side Setting) for product size control and automatic tramp iron release without stopping the crusher. | ROI Impact: Reduces unplanned downtime by up to 80% related to uncrushable material and allows quick product changeovers to meet different order specs.

MultiDeck HighFrequency Screen | Technical Basis: Independent, variablefrequency vibrators on each screen deck | Operational Benefit: Provides precise separation of sticky or damp material common in Lagos’ humidity, increasing screening efficiency and product purity. | ROI Impact: Improves yield of inspec material by an estimated 1525%, reducing waste and maximizing saleable tonnage.

Centralized Greasing & PLC Control System | Technical Basis: Automated lubrication circuits paired with programmable logic controller monitoring | Operational Benefit: Ensures critical bearings receive timed lubrication, while operators monitor plant performance from a single cabinet with fault diagnostics. | ROI Impact: Extends component life by up to 30% and reduces manual maintenance labor hours by approximately 20 hours per week.

AbrasionResistant Material Conveying | Technical Basis: AR400 steel liners at transfer points, 3ply EP conveyor belts with ceramic lagging on drive pulleys | Operational Benefit: Withstands the highly abrasive nature of Lagos granite, drastically reducing wearrelated tears and spillage. | ROI Impact: Lowers conveyor maintenance costs and belt replacement frequency by an estimated 40% annually.

Integrated Dust Suppression System | Technical Basis: Nozzle arrays at all transfer points fed by a highpressure pump system with water tank capacity for multiple shifts| Operational Benefit: Actively controls airborne particulate at each stage of processing, supporting compliance with environmental considerations for quarry sites in Lagos.| ROI Impact: Mitigates risk of operational delays due to environmental complaints and protects vital machinery from dust ingress.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Lagos Region) | Our Quarry Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Uptime Availability | ~7580%, frequent belt/liner wear stops | Target >92%, via abrasionresistant design & automated monitoring| +15%+ operational time |
| Tons per Hour Yield (InSpec)| Variable; screening inefficiency can lose ~15% yield| Consistent output; highfrequency screens optimize separation| +18% saleable material per ton fed |
| Energy Consumption per Ton| Fixedspeed drives across conveyors & crushers| PLCoptimized VFDs on conveyors & auxiliary systems| 12% average power draw |
| Maintenance Labor Hours/Month| High due to manual greasing & reactive repairs| Reduced via centralized lube systems & predictive diagnostics| 25% scheduled labor |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 150 – 400 TPH (tons per hour) of finished aggregate.
Power Requirements: Total installed power between 350 – 600 kVA, dependent on configuration. Designed for stable operation on industrial grid or largecapacity generator sets.
Material Specifications: Crusher mantles/concaves in Mn18Cr2 or Mn22Cr2 steel; structural steelwork primed with epoxy anticorrosion coating suitable for coastal/humid environments.
Key Physical Dimensions (Typical Setup): Plant footprint approx. 35m L x 22m W x 15m H (including conveyors). Modular design allows phased installation.
Environmental Operating Range: Designed for ambient temperatures of 20°C – 45°C; humidity up to 95%; dust suppression system rated for operation within local regulatory guidelines.

6. APPLICATION SCENARIOS

LargeScale Granite Quarry (Lekki Axis) | Challenge: Inability to meet simultaneous demand for multiple aggregate grades from major road contractors and batching plants, leading to lost contracts and high transport costs from distant processing sites.| Solution: Deployment of a 300 TPH tertiary crushing & screening plant with four final product conveyors.| Results: Enabled onsite production of four certified aggregate grades concurrently. Reduced reliance on external processors, increasing margin per ton by over 22% within one fiscal year.

MidSize Quarry Expanding Product Line (Ibadan Expressway Corridor)| Challenge: Existing twostage plant produced only base material; market demand was shifting towards highervalue washed aggregates for concrete.| Solution: Integration of our secondary/tertiary plant module with a fines recovery screw classifier system.| Results: Added three premium aggregate products to their catalog without expanding primary extraction volume. Captured new contracts from two major readymix companies within six months.

7. COMMERCIAL CONSIDERATIONS

Equipment Pricing Tiers: Capital expenditure scales with capacity automation level:
Tier A (150200 TPH): Standard configuration with manual adjustments.
Tier B (250350 TPH): Recommended configuration featuring PLC control semiautomated setting adjustment.
Tier C (400+ TPH): Full plant automation advanced wear monitoring telemetry capabilities.
Optional Features: Onboard diesel power pack genset), washing scrubber attachment dust extraction baghouses specific stockpile capacity radial stackers extended length).
Service Packages: Available options include annual preventive maintenance contracts guaranteed spare parts delivery timeslot priority technical support packages comprehensive operator training programs conducted onsite Lagos).
Financing Options: Collaboration financial institutions can facilitate equipment leasing structures capital loans tailored project finance solutions typical terms ranging months).

8.FAQ

1.Q:What if my primary crusher output size varies?
A:The surge hopper buffer capacity our secondary circuit designed handle reasonable feed variation The hydraulic adjustment cone crusher can compensate realtime maintain consistent product size

2.Q How quickly can this plant be commissioned after delivery?
A With complete foundation drawings prepared advance typical commissioning period supervised our engineers ranges weeks depending complexity This includes calibration full operator training

3.Q What are ongoing operational costs main wear parts?
A Primary consumables are crusher liners screen meshes conveyor skirting Based field data processing Lagos granite liner life expectancy ranges operating hours Cost per ton consumables provided detailed breakdown proposal

4.Q Is technical support available locally Lagos?
A We maintain dedicated service team based Lagos holding critical spare parts inventory Additionally remote diagnostic support available via PLC connection expedite troubleshooting

5.Q Can this plant be relocated another site future?
A Yes The modular skidmounted design allows disassembly relocation Major components engineered facilitate breakdown transport standard heavyduty trailers

6.Q What typical ROI period investment?
A Based historical projects similar scale key variables are your current cost outsourcing processing lost margin opportunity Improved efficiency reduced downtime typically yield ROI months depending utilization rate product pricing

7.Q Do you provide performance guarantees?
A Yes Our proposals include guaranteed minimum throughput capacity under defined conditions maximum power consumption per ton processed These backed contractual terms