Project Scope & Process Overview
Proposal: 100 TPH Hard Rock Crushing & Screening Plant
Target Region: Central / Eastern Uganda (Kampala, Jinja, Tororo corridors)
Application: Heavy Infrastructure Aggregates (0–5 mm, 5–10 mm, 10–20 mm, 20–30 mm)
Ugandan granite exhibits high compressive strength (>200 MPa) and high silica content, making it extremely abrasive. To minimize wear costs and eliminate excessive downtime caused by traditional impact crushers, this proposal utilizes a two-stage crushing circuit featuring a primary Jaw Crusher paired with a high-efficiency Secondary Hydraulic Cone Crusher .
Process Flow Diagram
Equipment Specifications
1. Primary Feeder & Crusher
- Heavy-Duty Vibrating Feeder (1 Unit)
- Model: GF0942S (with double-deck screen)
- Funnel Size: 900 × 4200 mm
- Max Feed Size: 500 mm
- Capacity: Up to 280 t/h
- Motor Power: 2.9 × 2 kW (5.8 kW energy-saving drive)
- Function: Regulates raw granite flow into the primary PE-600x900 jaw crusher while efficiently screening out dirt and sub-5mm soil fines.
- Primary Heavy-Duty Jaw Crusher (1 Unit)
- Model: PE-600×900
- Feed Opening: 600 × 900 mm
- Max Feed Size: 500 mm
- CSS Adjustment Range: 65–150 mm
- Motor Power: 75 kW
- Jaw Plate Material: High-Manganese Steel (Mn18Cr2) for maximum resistance to abrasive granite.
2. Secondary Crusher & Screening
- Secondary High-Efficiency Hydraulic Cone Crusher (1 Unit)
- Recommended Model: HST100 (Single-Cylinder) OR HPT100/HPT200 (Multi-Cylinder)
- Max Feed Size: 135–185 mm
- Closed-Side Setting (CSS): 8–25 mm
- Motor Power: 90–160 kW
- Features: Fully automated hydraulic discharge setting adjustment, tramper protection, and laminated crushing for superior cubical aggregate shape.
- Wear Liners: Heavy-duty Mn18Cr2 / Mn22Cr2 Mantle & Bowl Liners.
- Heavy-Duty Circular Vibrating Screen (1 Unit)
- Model: 3YK-1860 (3 Decks)
- Screening Area: 1.8 m × 6.0 m
- Decks Configuration: Deck 1 (30 mm), Deck 2 (20 mm), Deck 3 (10 mm), Bottom (5 mm)
- Motor Power: 22 kW
3. Material Handling & Electrics
- Belt Conveyors System (6 Units Total):
- C1 (Feeder to Jaw): B800 × 12 m (7.5 kW)
- C2 (Jaw to Cone): B800 × 22 m (11 kW)
- C3 (Cone to Screen): B800 × 24 m (11 kW)
- C4 (Oversize Return to Cone): B650 × 18 m (5.5 kW)
- C5–C8 (Product Stockpile Conveyors): 4 × B500 × 15 m (4 × 4 kW)
- Central Electric Control System: Fully integrated PLC control panel with touch screen interface, soft starters for primary motors, overload relays, and star-delta starters.
Site Layout Plan & Civil Requirements
- Footprint Requirement: Minimum 80 m × 35 m flat clearing, plus extra stockpiling radius for wheel loaders and tippers.
- Orientation: Position the primary hopper to align with the site's natural topography or build a 4–5 meter reinforced earth ramp for 20-ton tipper trucks.
- Civil Foundations: Requires approximately 120 m³ of C30/C35 grade reinforced concrete (RC) for the jaw and hydraulic cone foundations to absorb high dynamic vibration loads.
Capital Outlay & Localized Budget
| Item | Description | Cost Estimate (USD) |
|---|---|---|
| Machinery Package | Complete equipment set (Feeder, Jaw, HST/HPT Cone, Screen, Conveyors, PLC Panel) | $175,000 – $210,000 |
| Logistics & Duty | Shipping (3x40HQ Containers) to Mombasa + Transit clearance to Uganda | $22,000 – $28,000 |
| Civils & Earthworks | Local concrete, steel rebar, site levelling, and ramp construction | $15,000 – $22,000 |
| Power Installation | 300 kVA Diesel Generator OR Dedicated UMEME 315 kVA Transformer | $18,000 – $28,000 |
| Installation & Setup | Factory engineer deployment for 21 days (flight, stipend, site cranes) | $8,000 – $12,000 |
| Total Plant CapEx | Turnkey Setup Cost (Excluding Land & Mining Lease) | $238,000 – $300,000 |
Expected OPEX & Return Profile
- Installed Power: ~240 kW | Actual Operating Load: ~180–200 kW.
- Diesel Generation Cost (Uganda): ~$0.32 per ton.
- Wear Parts Cost (Granite): ~$0.40 – $0.45 per ton (HST/HPT hydraulic cones significantly cut wear consumption compared to spring cones).
- Net Production Cost: ~$3.20 / ton (includes raw rock blasting, fuel, wear parts, and site labor).
- Kampala/Jinja Market Price: ~$8.50 – $11.00 / ton.
- Estimated Payback Period: 9 to 13 Months operating on a single 8-hour shift per day.
Need a Customized 3D Layout & Official Quotation?
Every quarry terrain in Uganda is unique. Contact our engineering team today to receive a tailor-made CAD 3D layout plan, topographic site assessment, and formal equipment quotation for your project.
Frequently Asked Questions (FAQ)
Q1: What is the main difference between HST Single-Cylinder and HPT Multi-Cylinder Cone Crushers for Ugandan quarries?
A: The HST Single-Cylinder cone crusher is known for its simple structural design, ease of maintenance, and lower operational costs, making it highly reliable for secondary crushing. The HPT Multi-Cylinder cone crusher offers higher crushing forces and faster rotation speeds, achieving a higher reduction ratio and producing a greater percentage of fine cubical aggregate (such as 0–5 mm M-Sand).
Q2: Can this 100 TPH plant configuration produce Manufactured Sand (M-Sand) to replace scarce natural river sand in Uganda?
A: Yes. By adjusting the closed-side setting (CSS) of the HST/HPT cone crusher and optimizing the bottom deck of the 3YK-1860 vibrating screen to a 0–5 mm mesh, this plant efficiently produces high-grade M-Sand from granite fines, meeting local UNBS construction aggregate standards.
Q3: What generator capacity is needed if my quarry site in rural Uganda lacks UMEME grid power?
A: The complete 100 TPH plant has an installed electrical load of approximately 240 kW. We recommend deploying a 300 kVA or 350 kVA heavy-duty diesel generator set to ensure smooth motor starting torque and continuous site operation.
Q4: How do you handle wear parts delivery and technical support to avoid long plant downtime in East Africa?
A: We maintain a localized spare parts inventory (including high-manganese jaw plates, mantle/bowl liners, and screen meshes) in East Africa. Additionally, our field service engineers provide on-site installation, commissioning, and operator training.
