H1: Engineered for HighValue Recovery: Custom Gold Ore Crushing Solutions

1. PAINPOINT DRIVEN OPENING

Processing goldbearing ore presents distinct and costly challenges that standard crushing circuits often exacerbate. Are you facing these operational realities?

Recoverable Gold Loss in Fines: Conventional crushers can overgrind softer gold ore, creating ultrafine particles that are unrecoverable by gravity separation or leach circuits, directly reducing your overall yield.
Unscheduled Downtime from Abrasive Quartz: The high quartz content in many gold ores accelerates wear on crusher liners and components, leading to frequent, disruptive maintenance stops and high parts replacement costs.
Inefficient Throughput for Variable Feed: Hard rock, alluvial, and sulfide ores behave differently. A rigid plant struggles with feed variability, causing bottlenecks that limit tonsperhour capacity and increase energy cost per tonne.
High Operational Complexity: Does your process require multiple stages of jaw, cone, and impact crushing to achieve optimal liberation? This complexity increases footprint, manpower needs, and points of potential failure.

The central question is: how can you configure a crushing circuit that maximizes particle liberation for optimal recovery while minimizing wear costs and operational complexity? The answer lies in purposeengineered custom gold ore crushing equipment.

2. PRODUCT OVERVIEW

Our custom gold ore crushing equipment refers to engineeredtoorder primary and secondary crushing systems configured specifically for the mineralogy, feed size, and target product of your gold processing plant. The workflow is designed for efficient liberation:

1. Primary Reduction: Large runofmine ore is reduced to a manageable size using a robust jaw or gyratory crusher selected for its capacity and ability to handle abrasive material.
2. Secondary Liberation: The crushed material is fed into a cone crusher or specialized impactor tuned to produce a particle size that optimally exposes the gold for downstream cyanidation or gravity recovery.
3. Sizing & Recirculation: A vibrating screen classifies the output; onspec material proceeds to milling or leaching circuits, while oversize is recirculated for further reduction.

Application Scope: Ideal for greenfield projects, plant expansions, or retrofits targeting hard rock lode deposits (quartz veins), complex sulfide ores, and highvolume operations. Limitations: These are fixed or semimobile solutions requiring foundational support; not intended for smallscale artisanal mining or purely alluvial (placer) operations without associated hard rock feed.

3. CORE FEATURES

Patented Liner Geometry | Technical Basis: Finite Element Analysis (FEA) optimized wear profile | Operational Benefit: Redirects abrasive wear to replaceable cartridge sections, extending service life by up to 40% | ROI Impact: Reduces liner inventory costs and increases crusher availability for production

Variable Speed Drive (VSD) Control | Technical Basis: Precise adjustment of crusher eccentric speed | Operational Benefit: Allows operators to finetune the product gradation in realtime based on ore hardness changes | ROI Impact: Maintains optimal throughput and target P80 size consistently, improving downstream recovery efficiency

Tramp Metal Relief & Clearing | Technical Basis: Hydraulic adjustment and clearing systems with automated reversal cycles | Operational Benefit: Minimizes stall events from uncrushable material; clears chamber in minutes versus hours | ROI Impact: Prevents catastrophic damage and significantly reduces unplanned downtime events

Modular Wear Assembly Design | Technical Basis: Boltin, segmented wear components | Operational Benefit: Enables partial liner replacement during scheduled maintenance; reduces changeout time by over 30% | ROI Impact: Lowers labor costs per maintenance event and shortens production windows

Integrated Dust Suppression Manifold | Technical Basis: Sealed housing with directed spray nozzles at key transfer points | Operational Benefit: Effectively controls silica dust at source, improving site safety and regulatory compliance | ROI Impact: Reduces health risks and avoids potential fines related to airborne particulate

HighRatio Reduction Capability | Technical Basis: Engineered chamber profiles allowing larger feed opening relative to setting | Operational Benefit: A single unit can often replace two stages of conventional crushing in certain flowsheets | ROI Impact: Lowers capital expenditure footprint and simplifies the overall crushing circuit

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Custom Gold Ore Crushing Solution | Advantage (% improvement) |
| : | : | : | : |
| Liner Life in Abrasive Quartz Ore | 450 550 operating hours | 700 800 operating hours (with patented liners)| +40% |
| Crusher Availability (Uptime) | ~8590% (including unscheduled stops)| >94% (with advanced relief systems)| +59% absolute increase |
| Specific Energy Consumption (kWh/tonne)| Varies widely; less efficient multistage circuits average higher consumption.| Optimized singlestage or hybrid circuits reduce energy use.| Field data shows 1525% reduction possible |
| Optimal Product Yield (+/ target P80)| Often requires screening & recrush loops.| VSD control yields consistent product; reduces recycle load.| Up to 20% increase in firstpass yield |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 50 TPH pilot/test plant modules up to 1,200+ TPH productionscale installations.
Power Requirements: Dependent on configuration; primary units typically range from 75 kW to 400 kW. All drives are compatible with softstart technology for grid stability.
Material Specifications: Highchrome martensitic steel or manganese alloy wear liners standard; tungsten carbide options available for extreme abrasion zones. Fabricated main frames from ASTM A36 steel.
Physical Dimensions: Designs are sitespecific. Semimodular designs facilitate transport; typical primary unit footprint ranges from 25m² to 60m² including walkways.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +50°C. Sealed bearings and heated gear options available for extreme environments.

6. APPLICATION SCENARIOS

Hard Rock Lode Mine Expansion

Challenge: A mine expanding into a new quartz vein zone experienced rapid cone crusher liner wear (sub400 hours) and excessive sub100micron fines generation, hampering gravity recovery.
Solution: Implementation of a customconfigured secondary cone crusher with our patented liner geometry and a slightly modified chamber profile to produce a coarser product ideal for their Knelson concentrators.
Results: Liner life extended to 650 hours. Fines generation reduced by 18%. Gravity recovery circuit efficiency improved by an estimated 12%, significantly increasing revenue per tonne.

Sulfide Ore Processing Plant Retrofit

Challenge: An existing plant processing refractory sulfide gold ore had a bottleneck in their tertiary crushing stage, limiting feed to the grinding mill and causing throughput delays.
Solution: Replacement of two older tertiary crushers with one highcapacity custom gold ore crushing unit featuring VSD control. The system was integrated into the existing PLC network.
Results: Tertiary stage throughput increased by 35%. The VSD allowed optimization for varying sulfide/oxide blend ratios, stabilizing mill feed density. Overall plant throughput rose by an average of 22%.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers:
Standard Module Retrofit: For upgrading an existing crusher station with new technology liners/controls.
SemiMobile Skid Package: A preassembled crushing circuit on multiple skids for faster deployment.
Turnkey Station Design/Build: Full engineering, fabrication, installation, and commissioning of a custom circuit.

Optional Features & Upgrades: Advanced condition monitoring sensors (vibration/temperature), automated setting adjustment systems remote PLC integration packages premium ceramic composite wear components.

Service Packages: Tiered plans include scheduled inspection parts kits guaranteed response times for critical breakdowns remote diagnostics access.

Financing Options Available through partners include capital lease operating lease project financing terms tailored to mine development schedules.

8.FAQ

1.Q How do I determine if my operation needs "custom" equipment versus standard models?
A Customization becomes critical when your ore's abrasiveness work index or target product size falls outside the midrange performance envelope of catalog models An initial ore testing review can determine this need

2.Q What site data is required for an effective custom gold ore crushing equipment proposal?
A Provide details on your feed size distribution Bond Work Index abrasion index annual tonnage targets desired product P80 size any existing spatial constraints

3.Q Can these systems integrate with my existing PLC/DCS control room?
A Yes industrialstandard communication protocols Modbus TCP/IP Ethernet/IP allow full integration into most modern plant control systems providing operators with realtime data

4.Q What is the typical delivery lead time for a major custom unit?
A Lead times vary based on complexity For major primary units expect detailed engineering fabrication testing within a range of months following finalized design approval

5.Q How does the warranty structure work given the variable nature of ores?
A We provide base warranties on materials workmanship Performance warranties related specifically tonnage throughput under agreedupon feed conditions are structured as separate contractual guarantees

6.Q Are performance trials or pilotscale testing available before full commitment?
A Yes we offer rental pilot plants scaled testing at our facility using customerprovided bulk samples This provides definitive performance data before investment