H1: 500 TPH Gold Mining Washing Plant: Engineered for HighVolume, HighRecovery Operations

1. PAINPOINT DRIVEN OPENING

Scaling alluvial or placer gold operations to 500 TPH introduces distinct operational and financial challenges. Plant managers and engineering contractors face significant pressure to maintain profitability amidst variable feed material, rising operational costs, and stringent environmental regulations. Common pain points include:

Inconsistent Recovery Rates: Variable clay content and particle size distribution can lead to gold losses in fines or to tailings, directly impacting revenue. A 2% loss in recovery at 500 TPH can equate to substantial annual revenue forfeiture.
Excessive Downtime & Maintenance: Inadequate scrubbing, poor screen design, or underpowered components lead to frequent clogging, wearrelated failures, and unplanned stoppages, crippling your throughput targets.
High Water & Power Consumption: Inefficient washing and screening processes consume excessive resources, escalating operational expenses and complicating water management in waterscarce regions.
Difficulty Handling Problematic Material: Sticky clay, cemented gravels, and large oversize material can bring a conventional trommel or scrubber to a halt, creating bottlenecks before material even reaches the concentration stage.
Rapid Asset Depreciation: Equipment not built for 24/7 mining duty suffers from accelerated wear, leading to higher longterm capital replacement costs.

Are you seeking a washing plant solution that delivers consistent 500 TPH throughput while maximizing recovery and controlling the total cost of ownership?

2. PRODUCT OVERVIEW

A 500 TPH Gold Mining Washing Plant is a complete modular processing system designed for the primary beneficiation of alluvial gold deposits. Its core function is to liberate gold from waste gravels and clays through rigorous scrubbing and efficient size classification, preparing a concentrated feed for downstream recovery units like sluices, jigs, or centrifugal concentrators.

Operational Workflow:
1. Primary Feed & Scalping: Runofmine (ROM) material is fed via dump truck or loader into a robust hopper with grizzly bars to remove extreme oversize (>200mm).
2. Aggressive Scrubbing & Clay Disintegration: Material enters a heavyduty rotary scrubber or trommel screen where highimpact lifters and continuous water spray break apart cemented aggregates and dissolve sticky clays.
3. Primary Size Classification: The scrubbed ore reports to a vibrating screen deck (typically within the trommel or as a separate unit) to separate the target size fraction (e.g., 20mm +2mm) containing liberated gold.
4. Secondary Washing & Dewatering: The undersize slurry may pass through additional log washers or hydrocyclones for further cleaning before being directed to the recovery circuit. Screw classifiers or dewatering screens produce a manageable pulp density.
5. Waste Stream Management: Oversize rocks (+75mm) are conveyed to waste stockpiles, while processed fines and silt are managed in settling ponds or tailings storage facilities.

Application Scope & Limitations:
This plant is optimal for largescale alluvial/placer deposits with significant clay content requiring intensive washing. It is not suitable for hard rock (lode) mining without prior crushing circuits. Performance is contingent on accurate feed characterization—particularly clay percentage, moisture content, and abrasiveness—during the design phase.

3. CORE FEATURES

HeavyDuty Rotary Scrubber | Technical Basis: Hightorque drive system with reinforced lifters | Operational Benefit: Ensures complete disintegration of cemented gravels and tough clay nodules without stalling | ROI Impact: Eliminates precrushing stages for many deposits, reducing upfront CAPEX and ongoing energy costs.

Modular SkidMounted Design | Technical Basis: Preassembled structural steel skids with integrated walkways and piping | Operational Benefit: Reduces onsite installation time by up to 40%, minimizes civil works foundation costs | ROI Impact: Faster commissioning accelerates timetorevenue; simplifies relocation between mine sites.

Tier3/TierFinal DieselElectric Power Pack | Technical Basis: Centralized diesel generators powering individual electric motors on each module | Operational Benefit: Provides operational flexibility in remote locations; significantly lower fuel consumption compared to direct diesel hydraulic drives | ROI Impact: Cuts fuel costs by an estimated 1525% over the plant's lifecycle.

Advanced Water Recycling System | Technical Basis: Multistage settling ponds with optional thickener/clarifier integration | Operational Benefit: Reduces fresh water makeup requirements by over 70%, ensuring compliance with environmental discharge regulations | ROI Impact: Lowers water sourcing costs and mitigates risk of regulatory shutdowns.

Intelligent Process Control Panel | Technical Basis: PLCbased monitoring of feed rate, motor amperage, water pressure, and pump speeds | Operational Benefit: Allows operators to optimize performance in realtime based on feed changes; provides early fault diagnostics | ROI Impact: Prevents catastrophic failures; maintains consistent throughput and recovery through informed adjustments.

AbrasionResistant Liner Package | Technical Basis: Highchrome iron liners in scrubber barrel; AR400 steel on chutes and hoppers; polyurethane screen panels | Operational Benefit: Extends service intervals for critical wear components in highabrasion environments | ROI Impact: Reduces annual spare parts expenditure by approximately 30% versus standard manganese steel.

Integrated Sampling System | Technical Basis: Automated crossstream cutter sampler on final tailings line | Operational Benefit: Provides continuous metallurgical accounting data to track plant performance and recovery efficiency | ROI Impact: Enables datadriven optimization decisions that can improve overall recovery by measurable percentages.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 500 TPH Plants | Our 500 TPH Washing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Clay Disintegration Efficiency (for medium plasticity clay) ~85% scrubbing efficiency ~95%+ scrubbing efficiency +1012% |
| Fresh Water Consumption ~4500 m³/day ~1350 m³/day 70% |
| Mean Time Between Failure (Critical Scrubber Bearings) ~2,000 operating hours ~3,200 operating hours +60% |
| OnSite Installation & Commissioning Time ~68 weeks ~45 weeks 33% |
| Overall Recovery Efficiency (Liberated Au >100 micron) Varies widely; often unoptimized Consistently >98% capture in controlled feed Up to 8% improvement |

Field data shows overall site recovery is dependent on correct downstream concentration equipment selection.

5. TECHNICAL SPECIFICATIONS

Nominal Throughput Capacity: 500 metric tons per hour (dry feed basis).
Feed Material Size: Up to 200mm (subject to grizzly spacing).
Power Requirements: Total installed power ~750 kW. Typically supplied by dual 500 kVA diesel generator sets or grid connection.
Water Requirements: System makeup water requirement approximately 1,800 – 2,200 US GPM depending on clay content; heavily reduced with closedcircuit recycling.
Key Material Specifications:
Scrubber Drum Shell: 16mm mild steel with bolton highchrome liner segments.
Screen Decks: Polyurethane modular panels on primary sizing deck.
Structural Steelwork: ASTM A36 painted with industrial epoxy primer.
Slurry Pumps : Heavyduty rubberlined centrifugal pumps.
Physical Dimensions (Modular): Approximate footprint of main processing modules is 35m L x .20m W x .15m H.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust suppression sprays are standard at transfer points.

6. APPLICATION SCENARIOS

West African Alluvial Gold Project

Challenge A new concession with high lateritic clay content was causing severe blinding in competitor's screening equipment,
leading to daily downtime for manual cleaning
and estimated gold losses of
15%
in the fine fraction due
to poor liberation
Solution Implementation of our
500 TPH washing plant featuring an extended residence time scrubber
and specialized screen media spray bars Results Achieved sustained design throughput within three days of commissioning Claybound agglomerates were fully broken down resulting in a measured liberation efficiency increase that contributed directly
to an overall site recovery improvement from
82%
to
89%

LargeScale Placer Mine Relocation North America Challenge A contractor needed

to relocate their entire processing operation between two distant sections of a river valley within a single seasonal shutdown period minimizing lost production Solution Procurement of our skidmounted modular washing plant designed for rapid demobilization transport,
and reassembly Results The plant was disassembled transported over
300 miles,
and recommissioned at the new site in under seven weeks compared
to an estimated fourteen weeks required for their previous fixedstructure plant

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around core configuration:

Base Configuration Tier Includes primary scalping heavyduty scrubber trommel screen vibrating sizing deck basic walkways,
and control panel Starting investment aligns with industry standards for engineered equipment of this scale

Optional Features Upgrade packages include:
Advanced Water Management Module automated thickener polymer dosing system)
Premium Wear Liner Package extended life ceramic composite options)
Onboard Laboratory Sampling Station)
Spare Parts Starter Kit)

Service Packages:
Commissioning Supervision field technician support during startup)
Annual Preventive Maintenance Inspection scheduled inspections parts inventory planning)
Remote Monitoring Support subscriptionbased access

Financing Options We work with international export credit agencies project finance specialists,
and equipment leasing companies

8 FAQ

What upstream equipment is required To achieve consistent feeding we recommend frontend loaders minimum bucket capacity

Is this plant compatible Can be configured discharge slurry directly into sluice boxes jigs centrifugal concentrators pulp density optimized

What are typical operating labor requirements For steadystate operation one control room operator two field inspectors conducting rounds per shift

How do you guarantee performance Our process engineering team conducts comprehensive analysis prior finalizing design Performance expectations based testwork outlined detailed process guarantee document prior contract execution

What delivery timeline Delivery exworks months from order confirmation subject final engineering approval Shipping logistics managed through partners

Do you provide training Yes comprehensive classroom practical training provided commissioning covering operation maintenance troubleshooting safety procedures