Targeting Sustainable Quarry Operations in Lagos: HighEfficiency Mobile Crushing & Screening Plants

1. PAINPOINT DRIVEN OPENING

Operating a quarry site in Lagos presents distinct challenges that directly impact profitability and operational viability. Are you managing:
Escalating Operational Costs: Unpredictable fuel consumption from inefficient, aging equipment and the high expense of transporting raw material to a fixed processing site.
Site Inflexibility & Downtime: Significant revenue loss when primary crushers are down for maintenance, or when you need to relocate processing to follow aggregate seams, resulting in days of nonproduction.
Strict Environmental & Community Constraints: Pressure to minimize dust, noise, and land footprint within Lagos’s rapidly developing periurban areas, alongside the need for rapid site rehabilitation.
Inconsistent Aggregate Quality: Difficulty in meeting precise grading specifications for concrete and road base due to outdated screening technology, leading to product rejection or reduced market value.
High Logistics Complexity: Coordinating multiple machines (excavator, primary crusher, screen, conveyors) that are not designed as an integrated system, creating bottlenecks and management overhead.

How do you increase yield and reduce costperton while adhering to stricter environmental standards and maintaining operational flexibility?

2. PRODUCT OVERVIEW

Our solution is a trackmounted Mobile Crushing and Screening Plant engineered for sustainable quarrying. This integrated system moves directly to the rock face, eliminating dump trucks between the excavation point and primary crushing.

Operational Workflow:
1. Direct Face Feeding: An excavator loads blasted rock directly into the mobile plant's hopper at the quarry face.
2. OnSite Size Reduction: The material undergoes primary and often secondary crushing directly on the tracks.
3. Precise Sorting: Integrated highcapacity screens separate crushed material into precisely graded fractions (e.g., 05mm, 510mm, 1020mm).
4. Stockpiling & Relocation: Finished aggregates are conveyed to designated stockpiles. The entire plant can be relocated under its own power in under 30 minutes.

Application Scope: Ideal for mediumtolarge scale granite, limestone, or laterite quarry operations requiring multiple aggregate products. Suitable for greenfield sites and established pits where moving processing points is necessary.

Limitations: Not designed for ultrahard abrasive ores without specific liner configurations. Maximum singlefeed size is determined by plant model; oversize boulders may require prebreaking.

3. CORE FEATURES

Direct Feed System | Technical Basis: Optimized hopper geometry and feeder speed control | Operational Benefit: Eliminates wheel loader intermediary handling, reducing fuel burn by approximately 18% on loading cycles | ROI Impact: Direct reduction in fleet fuel costs and loader maintenance.

Hybrid Power Option | Technical Basis: Dieselelectric drive with onboard genset; plugin capability | Operational Benefit: Enables connection to grid power onsite for stationary periods, cutting fuel consumption by up to 60% during screening/conveying phases | ROI Impact: Major operational expenditure reduction in areas with stable grid access; lower carbon footprint.

Advanced Dust Suppression | Technical Basis: Pressurized water spray system with nozzles at all transfer points, combined with sealed conveyor skirts | Operational Benefit: Meets Lagos State environmental regulations for particulate emissions without reliance on weatherdependent external systems | ROI Impact: Avoids regulatory fines and facilitates smoother community relations and permit renewals.

Intelligent Process Control | Technical Basis: PLCbased system with touchscreen interface monitoring crusher load, pressure, and power draw | Operational Benefit: Operators optimize feed rate automatically to prevent blockages or run empty; realtime diagnostics reduce troubleshooting time by an average of 40% | ROI Impact: Higher machine availability and increased throughput of saleable product.

Rapid Relocation Capability | Technical Basis: Trackmounted chassis with hydraulic folding functions for conveyors and screen boxes | Operational Benefit: Full plant relocation between faces or sites can be completed within one shift by a minimal crew | ROI Impact: Maximizes resource extraction from confined leases and drastically reduces downtime during pit advancement.

HighGrade Screening Decks | Technical Basis: Multilayer vibrating screens with adjustable throw and tensioned rubber deck panels | Operational Benefit: Produces consistently graded aggregates that meet Nigerian industrial standards (NSI) for concrete work | ROI Impact: Commands premium pricing from readymix plants and largescale contractors; minimizes waste of offspec material.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Fixed / SemiMobile Plant) | Our Mobile Crushing & Screening Solution | Advantage (% Improvement) |
| : | : | : | : |
| Fuel Cost per Ton Processed| High (Dependent on truck fleet) | Low (Direct feed + hybrid option) | Up to 35% reduction |
| Relocation Time Between Faces| 35 days (Dismantle/Transport/Reassemble) | < 8 hours (Selfpropelled movement) | Over 90% faster |
| Setup Time on New Site| 12 weeks (Civil works required) | < 24 hours (Minimal ground leveling) | Approximately 95% faster |
| System Footprint| Large permanent area required| Compact; follows pit contour| Up to 60% smaller active area |
| Manpower Required for Operation| 46 personnel across multiple machines| 23 personnel via integrated control cabin| ~40% reduction |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Modeldependent throughput from 200 tph to over 450 tph of granite aggregate.
Primary Crusher Options: Jaw crusher (for high compressive strength rock) or impact crusher (for higher shape index requirements).
Power Requirements: Primary drive via Tier IV Final diesel engine (~350 kVA). Optional plugin connection for external electric power (400V/50Hz).
Key Material Specifications: Hardox® hopper and wear plates; highstrength steel frame; polyurethane screen deck panels for extended life.
Physical Dimensions (Operating): Approx. Length: 22m, Width: 3.5m, Height: 4.2m.
Environmental Operating Range: Designed for ambient temperatures of +5°C to +45°C; dust suppression system rated for operation up to 85% relative humidity.

6. APPLICATION SCENARIOS

Granite Quarry Expansion in Ikorodu Area

Challenge A quarry operator needed to access a new resource block separated by overburden from their existing fixed plant. Trucking raw material was costprohibitive.
Solution Deployment of a mobile crushing & screening plant directly at the new face location.
Results Eliminated a fleet of six dump trucks from the haul cycle. Reduced costperton by an estimated NGN ₦280 while increasing total site output by over NGN ₦22%. The site was fully operational within two days of equipment arrival.

Urban Perimeter Quarry with Noise/Dust Restrictions

Challenge A quarry operating near residential development faced stringent limits on operational hours due to noise complaints.
Solution Implementation of a mobile plant equipped with advanced sounddampening enclosures on crushers/screens and the integrated dust suppression system allowed processing closer to the active face.
Results Demonstrated compliance with regulatory decibel limits at the property boundary through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours Results demonstrated compliance through thirdparty testing secured extended operating hours , increasing weekly production volume by NGN ₦15%. Community complaints dropped significantly.

7. COMMERCIAL CONSIDERATIONS

Equipment is offered in three primary tiers based on capacity:
1. Standard Performance Tier
2.HighCapacity Tier
3.Custom Configuration Tier

Optional features include magnetic separators , additional fines washing modules , wireless remote controls ,and upgraded generator sets .

Service packages range from basic scheduled maintenance plans offered comprehensive uptime guarantees including parts kits held locally in our Lagos depot .

Financing options are available including leasetoown structures tailored typically over NGN ₦36NGN ₦60 months as well as partnership models based on production volume .

8.FAQ

What is required infrastructure wise?
The mobile plant requires reasonably stable compacted ground . Minimal civil works are needed beyond basic leveling . Access roads must accommodate standard lowbed trailer dimensions if transport between sites is necessary .

How does particle shape compare fixed cone crushers?
Modern mobile impact crushers equipped advanced rotor designs produce cubical product suitable most concrete applications . For extremely critical shape requirements jawcrusher based mobile units are recommended .

What typical lead time delivery commissioning?
From order confirmation delivery typically occurs within NGN ₦14NGN ₦18 weeks . Commissioning supervised our engineers takes approximately NGN ₦5 working days including operator training .

Are spare parts readily available Nigeria?
Yes we stock critical wear parts consumables our dedicated Lagos warehouse ensuring nextbusinessday availability most common items reducing potential downtime .

Can this equipment process laterite effectively?
Yes but configuration recommendations differ . For laterite applications we recommend specific screening media feed arrangements prevent clogging ensure optimal efficiency .