Targeted Solutions for HighValue Ore Processing: Bespoke Gold Ore Crushing Equipment

1. PAINPOINT DRIVEN OPENING

Processing goldbearing ore presents distinct and costly challenges that directly impact your bottom line. Are your current crushing solutions equipped to handle them? Common operational hurdles include:

High Abrasion & Premature Wear: Quartz and other hard gangue materials in gold ore rapidly degrade standard crusher liners and components, leading to frequent maintenance stops, high spare parts costs, and unplanned downtime.
Inefficient Liberation of Gold Particles: Inadequate or inconsistent size reduction fails to fully liberate gold from the host rock, trapping valuable material in larger fractions and reducing overall recovery rates in downstream leaching or gravity circuits.
Throughput Bottlenecks with Variable Feed: Fluctuations in ore hardness and feed size can choke standard crushers, creating bottlenecks that limit mill feed and constrain total plant capacity.
Contamination Risks: Certain crushing mechanisms can generate excessive heat or iron contamination from worn steel, which may interfere with subsequent chemical processes like cyanidation.

The central question for plant managers is this: how can you achieve consistent, optimallysized product while controlling wear costs and maximizing mineral liberation for recovery? A generic crushing system is often a compromise. A bespoke gold ore crushing system is engineered as the solution.

2. PRODUCT OVERVIEW

This product line comprises customconfigured primary and secondary crushing stations specifically engineered for gold ore processing. The systems are designed around robust jaw crushers, cone crushers, or highpressure grinding rolls (HPGR) selected and modified based on your ore characteristics.

Operational Workflow:
1. Primary Crushing & Scalping: Runofmine (ROM) ore is reduced to a manageable size (typically <150mm) while a vibrating grizzly removes fine material to bypass further crushing if suitable.
2. Secondary Crushing & Classification: The primary crushed product undergoes further reduction in a cone crusher or HPGR unit, calibrated to produce a specific product size range optimal for your milling or leaching circuit.
3. Product Sizing & Recirculation: Crushed material is screened; oversize material is recirculated back to the secondary crusher in a closed circuit to ensure strict control over final product sizing.

Application Scope: This equipment is designed for hardrock gold ores (lode deposits) containing quartz, sulphides, or other abrasive materials. It is integral to comminution circuits feeding ball mills, agitated leach tanks, or gravity concentration systems.

Limitations: These are stationary or semistationary plant solutions requiring foundational work and integration engineering. They are not designed for alluvial/placer operations where scrubbing and screening are primary processes.

3. CORE FEATURES

Advanced Liner Technology | Technical Basis: Highchrome white iron or manganese steel alloys with optimized profiles | Operational Benefit: Increases wear life by 3060% compared to standard liners in highabrasion applications | ROI Impact: Reduces liner changeout frequency and parts inventory cost, directly lowering costperton crushed.

Precision Chamber & CSS Control | Technical Basis: Hydraulic adjustment of the crusher’s closedside setting (CSS) with realtime monitoring | Operational Benefit: Operators can maintain precise product gradation despite changing ore conditions | ROI Impact: Consistent feed size improves downstream grinding efficiency and recovery rates by ensuring optimal mineral liberation.

Tramp Metal Protection & Clearing | Technical Basis: Automated hydraulic release & clearing system for uncrushable material | Operational Benefit: Prevents catastrophic damage from bucket teeth, drill bits, or other tramp metal; clears chamber automatically without manual intervention | ROI Impact: Eliminates major repair events and associated production losses from stalled crushing lines.

Integrated Dust Suppression Sealing | Technical Basis: Positivepressure air sealing systems combined with water spray nozzles at transfer points | Operational Benefit: Contains silica dust at source, protecting worker health and reducing plant cleanup | ROI Impact: Lowers operational risk by supporting compliance with industrial hygiene regulations (e.g., OSHA/MSHA).

Condition Monitoring Ports | Technical Basis: Integrated sensor ports for continuous vibration, temperature, and pressure monitoring | Operational Benefit: Enables predictive maintenance scheduling based on actual component condition rather than fixed hours | ROI Impact: Transforms maintenance from reactive to planned, increasing mechanical availability by up to 15%.

Modular Wear Component Design | Technical Basis: Liners and wear parts engineered as modular assemblies with simplified locking mechanisms | Operational Benefit: Reduces liner changeout time by up to 40% through safer, faster procedures | ROI Impact: Cuts labor costs per changeout and shortens maintenance windows, increasing annual operating hours.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Bespoke Gold Ore Crushing Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Wear Life (Abrasive Ore) | Baseline (100%) – Standard Manganese Steel | Advanced Alloy & Profile Design | +40% to +60% |
| Crusher Availability (Uptime) | ~8590% (Scheduled & Unscheduled Stops)| >93% (via Predictive Maintenance & QuickChange Design)| +5 to +8 Percentage Points |
| Specific Energy Consumption| Baseline (100%) – Standard Jaw/Cone Circuit| Optimized Flow Sheet & HPGR Integration Potential| 15% to 25% |
| Product P80 Consistency (± variance)| ± 15% of target size due to wear & feed variation| ± 5% of target via CSS Automation & Control| +67% Improvement in Consistency |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH pilotscale modules to 1,200+ TPH highproduction stationary plants.
Power Requirements: Dependent on configuration; primarysecondary circuits typically range from 150 kW to 800 kW total installed power. Options for dualdrive motors on primary units available.
Material Specifications: Highabrasion contact surfaces utilize ASTM A532 Class III Type B chrome iron alloys or modified manganese steel. Structural frames are fabricated from heavyduty ASTM A36 steel plate.
Physical Dimensions: Modular designs tailored to site constraints. A typical secondary module footprint may range from 8m x 6m up to 15m x 10m including conveyors and support structure.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Sealed bearings and enclosed drives standard for highdust environments. Corrosionresistant coatings specified for humid or coastal sites.

6. APPLICATION SCENARIOS

Hard Rock Underground Mine Expansion

Challenge: An existing operation scaling up production faced bottlenecking at its surface crushing plant due to harderthanexpected ore zones from a new underground level. This caused erratic feed to the mill and increased liner costs by over 50%.
Solution: Implementation of a bespoke secondary crushing stage using a cone crusher with automated CSS control and ultrawearresistant liners specifically selected for the ore's Bond Work Index.
Results: Plant throughput stabilized at design capacity of 400 TPH. Liner life returned to original projections, reducing consumable costs by $35,000 per month. Consistent crusher product allowed the grinding circuit to operate at peak efficiency.

Heap Leach Operation Optimization

Challenge: A lowgrade heap leach operation struggled with poor percolation due to inconsistent crush size—too many fines ("ponding") and too many coarse rocks ("low recovery"). Their singlestage crusher could not achieve the narrow target range.
Solution: Installation of a custom twostage closedcircuit crushing plant featuring precise screening and recirculation logic tailored to produce a tightly controlled 19mm +6mm product stack.
Results: Achieved target crush size distribution with over 90% consistency. Improved solution flow increased overall gold recovery by an estimated 4%. Reduced cycle time on leach pads improved asset turnover.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Capital investment scales with capacity and complexity.
Tier 1 (Standard Module): Preengineered secondary/tertiary module with select alloy options.
Tier 2 (Full Circuit): Custom primarysecondary circuit with advanced automation controls.
Tier 3 (Integrated HPGR Solution): Highefficiency circuit featuring HPGR technology for specific energy reduction.
Optional Features: Onboard weighing instrumentation, advanced particle size analysis feedback loops remote telematics packages full PLC/SCADA integration spare parts starter kits
Service Packages: Annual inspection programs guaranteed parts supply agreements predictive maintenance analytics support onsite technician training programs
Financing Options: Available capital lease structures operating lease arrangements project financing support through partner institutions

8.FAQ

Q1 How do I determine if my operation needs a fully bespoke system versus a modified standard unit?
A1 The requirement hinges on your ore's abrasiveness variability Bond Work Indexand final product specification Our process begins with an analysis of your ore characterization dataand current plant performance metrics Standard modifications often sufficefor consistent ores; highly variableor refractory ores typically justifya fully bespoke design

Q2 What is the typical lead timefrom order commissioningfora custom goldorecrushingplant?
A2 Fora complete circuit lead timesrange from8to14months dependingon complexity This includes detailed engineering fabrication shop assembly testingand disassemblyfor shipment Modular designs can reduce onsite construction timeby upto30%

Q3 Can this equipment be integratedwith our existing millingor conveying infrastructure?
A3 Yes integration capabilityis acore design principle Our engineering team will reviewyour existing plant layoutand process flow sheetto ensure seamless interfacingwith feed systemsproduct conveyorsand control rooms

Q4 How arethe operational cost savingsROI quantifiedfor management approval?
A4 We providea detailed Total Costof OwnershipTCO modelbasedonyour specific data It quantifies savingsfrom reduced energy consumptionlongerwear partlife higher availabilityand improved downstream recovery againstthe capital investment Typical payback periods field data showsrange between18and36months

Q5 What levelof operator trainingis providedwiththe installation?
A5 Comprehensive trainingis included covering safe operation routine maintenance troubleshootingand control system interface Trainingis conductedfor both supervisorsand operators priorto handover withextended supportavailable

Q6 Are performance guarantees offeredwiththe equipment?
A6 Yes we provideguaranteesfor rated throughput power consumption under defined conditions wear part life under specified abrasion indicesand final product gradation Theseare contractually defined basedon the agreed process design criteria

Q7 What aftermarket supportis availableincluding parts availability?
A7 We maintaina global networkof service centersand certified parts warehouses Critical wear componentsare stockedagainstyour equipment serial numberto ensure fast turnaround Support contracts include24/7 remote technical assistance