1. PAINPOINT DRIVEN OPENING

Scaling gold recovery operations to 500 Tph presents distinct challenges that directly impact profitability. Inconsistent feed rates, high water consumption, and excessive downtime for maintenance can erode margins. Are you facing these issues?
Throughput Bottlenecks: Can your washing and scrubbing plant maintain a consistent 500 Tph feed without becoming a processing bottleneck, leading to pileup and lost production time?
High Operational Costs: Are you managing escalating costs from water procurement, recycling system complexity, and highenergy consumption in your material handling and separation processes?
Recovery Losses: Is inefficient scrubbing or claybound material causing precious gold fines to be lost to tailings, directly reducing your overall yield?
Unscheduled Downtime: Are frequent mechanical failures in scrubbers, screens, or pumps causing unpredictable stoppages, making production targets unreliable?

A robust 500 Tph gold mining washing plant is engineered to address these exact operational challenges.

2. PRODUCT OVERVIEW

This product is a highcapacity, modular washing plant designed for alluvial and eluvial gold deposits. Its primary function is to liberate gold from claybound gravels and efficiently separate valuable material from waste through scrubbing, screening, and gravity concentration.

Operational Workflow:
1. Primary Feed & Scrubbing: Runofmine (ROM) material is fed into a heavyduty trommel or scrubber, where intense agitation breaks down clays and cemented aggregates.
2. Sizing & Classification: The disaggregated material passes over vibrating screens, separating +2mm to +10mm (sitespecific) oversize (waste rock) from the valuable undersize fraction.
3. Concentration & Recovery: The undersize slurry is routed to primary gravity concentrators (e.g., sluices, jigs) for initial gold recovery. Tailings may pass through secondary scavenging units.
4. Water Management & Tailings: Process water is clarified in a settling system for recirculation, minimizing fresh water intake. Waste streams are managed for responsible disposal.

Application Scope & Limitations:
Scope: Ideal for largescale alluvial/eluvial operations, placer deposits, and weathered conglomerates where clay removal is essential prior to cyanidation or further processing.
Limitations: Not suitable for hard rock lode deposits without prior crushing. Performance is highly dependent on feed material characteristics (clay content, plasticity, rock size).

3. CORE FEATURES

HeavyDuty Scrubber Module | Technical Basis: Hightorque drum with internal lifters | Operational Benefit: Ensures complete disintegration of clay agglomerates and cemented gravels at full 500 Tph feed rate | ROI Impact: Maximizes gold liberation from the start, reducing losses to tailings and improving overall recovery rate.

Modular Vibrating Screen Deck | Technical Basis: Multistage screening with replaceable polyurethane panels | Operational Benefit: Provides precise size classification under high load; panels resist blinding and wear | ROI Impact: Reduces screen replacement frequency by up to 40% versus standard rubber panels, lowering parts inventory costs and maintenance downtime.

Integrated Water Recycling System | Technical Basis: Multicompartment settling tanks with flocculant dosing | Operational Benefit: Recovers up to 85% of process water for immediate reuse | ROI Impact: Cuts freshwater procurement and pumping costs significantly; reduces environmental footprint and licensing complexity.

Centralized Grease & Lube System | Technical Basis: Automated manifold delivering grease to all critical bearings | Operational Benefit: Ensures optimal bearing life on scrubber trommel rollers screen vibrators under highload conditions | ROI Impact: Prevents catastrophic bearing failures extends component service intervals by approximately 30% reducing unscheduled stoppages.

PLCBased Control & Monitoring Panel | Technical Basis: Programmable Logic Controller with touchscreen HMI displaying motor loads feed rates amp draws | Operational Benefit: Gives operators realtime visibility into plant performance enabling quick adjustments fault diagnosis | ROI Impact: Optimizes power consumption allows predictive maintenance scheduling improves overall operational efficiency.

QuickDisconnect Module Couplings | Technical Basis: Standardized flanges pipe connections between scrubber screen pump modules | Operational Benefit: Enables rapid reconfiguration or module replacement during planned maintenance or site relocation | ROI Impact: Reduces plant recommissioning time by days during moves directly increasing productive uptime.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 500 Tph Plants | Our Washing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Water Consumption (m³/tonne) | 3.0 4.0 m³/tonne processed| ≤ 2.5 m³/tonne processed| Up to ~38% reduction |
| Target Availability (Scheduled Runtime) |>90% |>95% |>5 percentage points |
| Clay Disintegration Efficiency (for medium plasticity) |>85% |>95% |>10 percentage points |
| Relocation & Reassembly Time (for modular plants)| ~1421 days| ~710 days| ~50% faster |
| Specific Energy Consumption (kWh/tonne)| Varies widely; optimized design can reduce by ~1520% versus nonintegrated systems.| |

5. TECHNICAL SPECIFICATIONS

Nominal Capacity: 500 tonnes per hour (Tph), design allows for peak feeds of up to 550 Tph.
Power Requirements: Total connected load approximately 650800 kW dependent on configuration voltage supplied at client specification (e.g., 11kV /50Hz).
Material Specifications: Abrasionresistant steel (AR400) in chutes hoppers; Highdensity polyurethane on screen decks launders; Certified wearresistant piping.
Physical Dimensions (Modular): Scrubber Module (~12m L x 4m W x 4m H); Screening Module (~10m L x 4m W x 4m H). Overall footprint varies with layout.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C dust suppression systems standard can be configured for highaltitude operation.

6. APPLICATION SCENARIOS

West African Alluvial Gold Operation

Challenge A major operation faced severe claybinding in its deposit causing existing rotary scrubbers to “log” frequently reducing effective throughput below 96%. Plant sustained consistent >480 Tph throughput annual gold recovery increased by an estimated >8% due to improved liberation reduced oversize losses.

Southeast Asian LargeScale Placer Mine

Challenge Extremely high freshwater costs remote location required minimal water usage frequent cyclone blockages caused excessive maintenance downtime.
Solution A complete washing plant featuring an advanced multistage settling system with automated flocculant dosing highly accessible cyclone cluster design.
Results Freshwater consumption reduced by over >70%. Cyclone maintenance intervals extended from weekly monthly availability of the washing section increased >92%.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Capital cost varies based on scope:
Base Tier Includes core scrubber screening deck primary recovery sluices basic control system
Enhanced Tier Adds secondary gravity scavenging advanced PLC control automated lubrication
FullCircuit Tier Includes complete water recycling/tailings management system turnkey commissioning support

Optional Features: Diesel power modules remote monitoring telemetry dust encapsulation covers specific oretesting package

Service Packages Annual inspection parts kitting programs guaranteed critical parts availability (<48hr dispatch) onsite technician support contracts

Financing Options Equipment leasing structures operating lease agreements project financing facilitation through partner institutions

8. FAQ

What feed size can the plant handle? The standard configuration accepts ROM material up to approximately <250mm optimal feed size is <150mm For larger material a grizzly or primary scalping unit is recommended

How does the plant handle variations in clay content? The scrubber module’s drive system is designed with variable speed control allowing operators adjust retention time drum speed based realtime feed characteristics maintain optimal breakdown

What are the typical installation requirements? A level prepared pad adequate foundations utilities connections The modular design allows phased installation We provide detailed foundation general arrangement drawings part of engineering package

Are spare parts readily available? Yes Critical wear parts common mechanical components are standardized held global stock Strategic partners maintain regional warehouses ensure supply chain reliability

Can this plant be integrated with existing downstream processes? Yes The plant designed as standalone circuit can be configured discharge concentrated slurry directly into your existing cyanidation circuit leach tanks simply pass upgraded concentrate further processing