As Nigeria undergoes rapid urbanization, the construction industry continues to see growing demand for high-quality sand and aggregate. To address this growing market need, AIMIX developed a customized crushing solution for a local company. The project was initiated in 2023 and successfully commenced production in 2025.
Project Starting Point: Urban Rise and Industrial Opportunities
Nigeria is at a critical stage of urban development. Coastal cities like Lagos, in particular, are seeing a surge in construction projects, with infrastructure development including roads, housing, and ports proceeding at a rapid pace. However, the local aggregate production system faced issues such as limited capacity and inconsistent quality, making it difficult to keep up with rising market demand.
With years of experience in Nigeria’s construction industry, the local company accurately identified the considerable potential of the aggregate market. To enhance self-sufficiency and ensure material quality, the company decided to introduce a 250 tph stone crusher plant. Through standardized and large-scale operation, Iche sought to provide a reliable and steady supply of aggregates for local construction projects.
Key Challenges Faced by the Project
Complex Raw Material Properties
Local ores mainly consist of granite and basalt, with a Mohs hardness of 6 to 7 and a compressive strength generally between 150 and 250 MPa. Conventional crushing equipment struggles to withstand the long-term, high-intensity crushing demands. As a result, the equipment wear out quickly and blockages occur frequently, making it difficult to maintain stable production.
Weak Infrastructure and Unstable Power Supply
Power supply poses another major challenge to production. Frequent outages disrupt the rock crushing plant, making continuous operation nearly impossible. Statistics show that the area experiences power cuts 5 to 8 times per month, each lasting several hours or even longer. Consequently, production plans often face repeated interruptions.
Lagging Logistics and Transport Obstacles
The limited road infrastructure in Nigeria further slows down transportation efficiency. This problem becomes even worse during the rainy season, when muddy roads lead to higher vehicle damage rates. As a result, the delivery of crushing equipment and spare parts takes much longer, delaying maintenance and repair schedules, and directly increasing the company’s operating costs.
Intelligent Collaboration to Overcome Challenges: AIMIX and Client’s Innovative Solutions
Facing the complex and diverse challenges during the project’s progress, the AIMIX technical team collaborated closely with the client, finding innovative solutions for every problem through systematic analysis, repeated trials, and decisive decision-making. From optimizing the crushing process and building a power supply system to the refined management of logistics and supply chain, every aspect embodies the team’s innovation and efforts, laying a solid foundation for the efficient and stable operation of the project.
Core Crushing Process Trials and Decisions: Finding the Optimal Crushing Solution
- Trial and Error Phase: Initially, the technical team experimented with various equipment combinations, including the traditional jaw crusher + cone crusher combination, and the newer impact crusher + vertical shaft impact crusher combination. Each trial involved detailed monitoring and data analysis of output particle size, particle shape, equipment wear, and energy consumption. This process was not without its challenges, as some solutions encountered bottlenecks in handling extreme hardness or controlling product quality.
- Final Decision: Based on the large amount of experimental data accumulated, the team ultimately determined the optimal combination of “hydraulic jaw crusher + spring cone crusher.” This decision carefully balanced efficiency, product quality, and equipment durability: the hydraulic jaw crusher, with its powerful crushing force and stability, handled the primary crushing; the spring cone crusher, with its precise cavity design and adjustability, ensured the production of high-quality aggregates with excellent particle shape and uniform gradation during the secondary and tertiary crushing stages.
Upgrading Operational Support: Building a Stable Support System
- Upgrading Power Supply: Faced with frequent power outages, the team initially tried using small uninterruptible power supplies (UPS) as a buffer. However, in actual operation, prolonged power outages made the UPS solution unsustainable. Therefore, the client made a crucial investment decision – introducing a large backup power generation system, enabling seamless switching during main power interruptions and fundamentally guaranteeing the continuous operation of the production line.
- Optimizing the Logistics System: To address efficiency and cost issues caused by transportation delays, the client proactively collaborated closely with local transportation partners. Through detailed road surveys and route mapping, they systematically planned and dynamically optimized transportation routes, while also selecting more adaptable vehicle equipment. Furthermore, a fast track was established with international logistics providers for critical spare parts, minimizing downtime caused by waiting for parts and creating an efficient and flexible supply chain support network.
Project Achievements and Industry Impact: From Production Line to Urban Development
After months of construction and commissioning, the 250tph crusher plant was successfully launched. The equipment operates efficiently and reliably, producing aggregates with uniform size and excellent shape, fully covering a range of specifications ranges, incliding 0–5mm, 5–13mm, 13–19mm, and 19–25mm. These high-quality aggregates are widely used in roadworks, residential, and commercial construction. Not only do they meet the demands of the Lagos market, but they also reach neighboring cities, serving as a vital resource for regional infrastructure projects.
Since the production line began operating, the superior product quality has quickly gained the trust of construction companies, continuously supporting major infrastructure and real estate projects. Meanwhile, the project has created local jobs and boosted the transportation sector, setting a replicable benchmark for Nigeria’s building materials industry. Through ongoing technological innovation and operational optimization, the client has transformed challenges into real value, emerging as a driving force behind the upgrade of the local construction supply chain.
Now is the perfect time to invest in a stone crusher plant in Nigeria. Let’s work together to turn challenges into new growth opportunities and unlock broader market prospects!
