1. PAINPOINT DRIVEN OPENING

Are you scaling up alluvial or hard rock gold operations but finding your recovery process a bottleneck? Managing a 500 TPH feed rate presents distinct challenges that directly impact profitability. Common operational hurdles include:
High Volume Inefficiency: Conventional scrubbers and trommels struggle with consistent feed and claybound materials at this scale, leading to frequent blockages, excessive water consumption, and lost fines.
Downtime for Maintenance: Plants requiring daily liner changes, screen cleaning, or complex bearing assemblies lose hundreds of tons of potential processing per hour. Unplanned stoppages can cost tens of thousands per day in lost revenue.
Low Recovery on Fine Gold: Simple screening and sluicing systems often fail to capture micron gold particles, sacrificing significant value. Industry estimates suggest inefficient plants can lose 1025% of recoverable gold to tailings.
High Operational Overheads: Systems dependent on multiple conveyors, complex water management, and large crew sizes erode profit margins.

Is your current setup maximizing recovery while minimizing operational cost per ton? Can your washing plant handle variable feed material without constant operator intervention? The solution requires robust engineering designed specifically for highvolume, highrecovery operations.

2. PRODUCT OVERVIEW

The 500 TPH Gold Mining Washing Plant is a modular, heavyduty scrubbing, screening, and gravity concentration system engineered for continuous, highcapacity operation. It is designed to liberate gold from alluvial deposits, eluvial materials, and weathered ore.

Operational Workflow:
1. Primary Scrubbing & Disaggregation: Feed material is introduced into a largediameter rotary scrubber, where robust lifters and highpressure water jets break down clay agglomerates and cemented gravels.
2. Primary Screening & Sizing: Discharged material is screened (typically at 10mm). Oversize (+10mm) barren rock is conveyed to waste. Undersize (10mm) slurry containing gold reports to the secondary circuit.
3. Secondary Screening & Concentration: The slurry passes over fine screening (e.g., 2mm) and/or a series of cascading sluices with optimized riffle design. Highdensity gold particles are trapped while lighter gangue material is washed away.
4. Tailings Management & Water Clarification: Waste slurry can be directed to a settling pond or optional cyclone/water recycling module to reduce freshwater demand.

Application Scope & Limitations:
Scope: Ideal for alluvial/placer deposits, riverbank operations, and soft rock saprolite zones with high clay content. Effective on particle sizes from nuggets down to +100 mesh fine gold.
Limitations: Not suitable for primary crushing of hard rock quartz veins or processing lateritic nickel ores without significant precrushing. Performance is contingent on appropriate feed size distribution and controlled clay content.

3. CORE FEATURES

HeavyDuty Rotary Scrubber | Technical Basis: Abrasionresistant manganese steel liners with optimal lifter design for maximum attrition | Operational Benefit: Effectively breaks apart tough clay balls and cemented gravel with minimal liner wear | ROI Impact: Reduces liner replacement frequency by up to 40%, lowering parts inventory costs and maintenance downtime.

Modular Trommel/Screen Deck | Technical Basis: Interchangeable screen panels (polyurethane or punch plate) on a rigid trunnion roller assembly | Operational Benefit: Allows rapid panel changeout (<2 hours) for different feed conditions and easy access for cleaning | ROI Impact: Increases plant availability by minimizing scheduled maintenance windows; adaptable to varying deposit characteristics.

Optimized Sluice Concentration System | Technical Basis: Laminar flow design with staged riffle types (Hungarian, expanded metal) and matting for fine gold retention | Operational Benefit: Creates optimal flow dynamics to capture a broad spectrum of gold particle sizes, including challenging fines | ROI Impact: Field data shows recovery rates improvement of 815% on sub150 mesh gold compared to standard designs, directly increasing revenue.

Centralized Greasing & Monitoring System | Technical Basis: Automated lubrication points on all major bearings with lowpressure alarms | Operational Benefit: Ensures critical components are protected from grit ingress without manual intervention | ROI Impact: Extends bearing service life by an estimated 300%, preventing catastrophic failures that cause multiday shutdowns.

LowPressure HighVolume Water System | Technical Basis: Strategically placed manifoldfed spray bars designed for maximum washing effect with minimal pump horsepower | Operational Benefit: Provides thorough material cleaning without eroding settled gold in the sluices or overloading the water circuit | ROI Impact: Can reduce process water consumption by approximately 25%, lowering pumping costs and environmental footprint.

BoltTogether Modular Design | Technical Basis: Fabricated structural modules with precision alignment pins and flanged connections | Operational Benefit Enables rapid site assembly (<10 days) with standard tools and reduces shipping complexity | ROI Impact Cuts installation labor costs by an estimated 35% and gets the plant generating revenue faster.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 500 TPH Plants | Our 500 TPH Washing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Average Availability | 8590% (downtime for maintenance/blockages) | 9496% (robust design & easy access) | +6% operational uptime |
| Fine Gold Recovery (<100 mesh)| Reliant on secondary circuits; often inconsistent| Engineered primary sluice capture| +12% estimated recovery rate |
| Liner Changeout Time| 812 hours (full crew)| <4 hours (modular panels)| 60% maintenance duration |
| Process Water Demand| ~4500 GPM at head pressure| ~3400 GPM via optimized spray pattern| 25% water consumption |
| OnSite Assembly Duration| 34 weeks with skilled welders| <10 days with bolted connections| 65% installation time |

5. TECHNICAL SPECIFICATIONS

Nominal Capacity: 500 Tons Per Hour (dry feed)
Feed Size Maximum: Up to 250mm
Power Requirements: ~450 kW total installed power (Main scrubber drive, screen motors, pumps)
Water Requirements: Approximately 3400 US GPM at 40 PSI
Material Specifications:
Scrubber Drum: 20mm mild steel shell with bolton AR400 liners
Screen Decks: Replaceable polyurethane panels
Sluice Trays & Riffles: Abrasionresistant aluminum or stainless steel
Structural Frame: Heavywall rectangular tubing
Physical Dimensions (approx., modular):
Scrubber Module: L12m x W5m x H5m
Screen/Sluice Module: L15m x W6m x H4m
Conveyor Modules: Variable lengths
Environmental Operating Range: Designed for 20°C to +50°C ambient temperature. Dust seals and covered walkways are standard.

6. APPLICATION SCENARIOS

Alluvial Placer Operation in West Africa | Challenge A contractor was losing an estimated $1M+ annually in unrecovered fine gold due to an outdated trommel/sluice system that couldn't handle sticky clay layers within the pay gravel.| Solution Implementation of the modular washing plant featuring the heavyduty scrubber section followed by the optimized sluice concentration system.| Results After commissioning throughput stabilized at a consistent >480 TPH despite variable clay content Fine gold recovery improved by an estimated >15%. Payback period was calculated at under eight months based on increased yield alone

Eluvial Deposit Processing in South America Challenge A mine expanding into a weathered saprolite zone faced high downtime from blockages in their existing plant's screening section causing inconsistent feed to gravity circuits Solution The plant was configured with an aggressive primary scrubber module followed by the modular trommel deck allowing quick clearing of any oversize accumulation Results Plant availability increased from ~82% to over >93%. The consistent feed improved downstream concentrator efficiency yielding a total site recovery increase of >9%

LargeScale Construction Aggregate Byproduct Recovery Challenge A sand gravel quarry operation identified payable gold in their fines stream but their existing cyclones were not designed for precious metal capture Solution Integration of a dedicated fines processing skid using principles from the washing plants concentration system into their existing wash plant flow Results The operation added a new revenue stream recovering between .5g1g Au per ton from previously discarded material adding significant margin without disrupting core aggregate production

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around core configuration:

Base Configuration Includes primary scrubbing primary screening waste conveyor basic sluice box Price positioned competitively against standard industry offerings

Enhanced Recovery Package Adds secondary fine screening advanced sluice matting/riffle systems nominal increase over base price delivers significantly higher ROI through improved recovery rates

Fully Modularized Skidded Plant All components including pumps control cabin piping pre mounted on transportable skids Premium investment reduces site installation time risk ideal for remote locations or contractors requiring relocation flexibility

Optional Features High G centrifugal concentrator tailings dewatering cyclone package automated dosing system for pH modification

Service Packages Proactive maintenance plans remote monitoring diagnostics operator training programs ensure optimal long term performance

Financing Options Available through partner institutions including equipment leasing operating lease agreements tailored capital expenditure solutions

8 FAQ

What is the minimum crew required to operate this washing plant?
The centralized controls automated lubrication allow efficient operation typically requiring one loader operator one plant monitor reducing labor costs compared older designs needing multiple attendants

How does this plant handle periods of highly abrasive feed material?
Wear components like scrubber liners screen panels are specified in abrasion resistant grades manganese steel polyurethane Field data supports component life exceeding industry averages under abrasive conditions though inspection intervals may adjust accordingly

Can this system be integrated into an existing CarboninLeach CIL circuit?
Yes It serves as an effective preconcentration device Many operations use it as a scalping unit ahead milling liberating coarse freegold reducing load capacity requirements downstream grinding leaching circuits improving overall circuit efficiency

What are typical delivery lead times?
For standard configurations lead time ranges from weeks depending current production schedule complexity Fully customized orders require additional engineering time discussed during project scoping

What site preparation is necessary before delivery?
A level compacted pad adequate foundations footings utilities power water supply drainage sump required Detailed site preparation specifications provided upon order confirmation