1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Are you scaling up alluvial or hard rock gold operations but finding your recovery process a bottleneck? Gestionar un 500 TPH feed rate presents distinct challenges that directly impact profitability. Los obstáculos operativos comunes incluyen:
High Volume Inefficiency: Conventional scrubbers and trommels struggle with consistent feed and claybound materials at this scale, leading to frequent blockages, consumo excesivo de agua, 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. DESCRIPCIÓN GENERAL DEL PRODUCTO

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

Flujo de trabajo operativo:
1. Fregado primario & Desagregación: Feed material is introduced into a largediameter rotary scrubber, where robust lifters and highpressure water jets break down clay agglomerates and cemented gravels.
2. Evaluación primaria & Apresto: Discharged material is screened (typically at 10mm). Demasiado grande (+10milímetros) barren rock is conveyed to waste. Undersize (10milímetros) slurry containing gold reports to the secondary circuit.
3. Evaluación secundaria & Concentración: The slurry passes over fine screening (p.ej., 2milímetros) and/or a series of cascading sluices with optimized riffle design. Highdensity gold particles are trapped while lighter gangue material is washed away.
4. Gestión de relaves & Water Clarification: Waste slurry can be directed to a settling pond or optional cyclone/water recycling module to reduce freshwater demand.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal para depósitos aluviales/placer, riverbank operations, and soft rock saprolite zones with high clay content. Effective on particle sizes from nuggets down to +100 mesh fine gold.
Limitaciones: 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. CARACTERÍSTICAS PRINCIPALES

Fregadora rotativa de servicio pesado | Base técnica: Abrasionresistant manganese steel liners with optimal lifter design for maximum attrition | Beneficio operativo: Effectively breaks apart tough clay balls and cemented gravel with minimal liner wear | Impacto del retorno de la inversión: Reduce la frecuencia de reemplazo del revestimiento hasta en 40%, Reducir los costos de inventario de piezas y el tiempo de inactividad por mantenimiento..

Modular Trommel/Screen Deck | Base técnica: Interchangeable screen panels (polyurethane or punch plate) on a rigid trunnion roller assembly | Beneficio operativo: Allows rapid panel changeout (<2 horas) for different feed conditions and easy access for cleaning | Impacto del retorno de la inversión: Increases plant availability by minimizing scheduled maintenance windows; adaptable to varying deposit characteristics.

Optimized Sluice Concentration System | Base técnica: Laminar flow design with staged riffle types (Hungarian, expanded metal) and matting for fine gold retention | Beneficio operativo: Creates optimal flow dynamics to capture a broad spectrum of gold particle sizes, including challenging fines | Impacto del retorno de la inversión: Field data shows recovery rates improvement of 815% on sub150 mesh gold compared to standard designs, aumentar directamente los ingresos.

Engrase centralizado & Sistema de monitoreo | Base técnica: Automated lubrication points on all major bearings with lowpressure alarms | Beneficio operativo: Ensures critical components are protected from grit ingress without manual intervention | Impacto del retorno de la inversión: Extiende la vida útil del rodamiento en un estimado 300%, preventing catastrophic failures that cause multiday shutdowns.

LowPressure HighVolume Water System | Base técnica: Strategically placed manifoldfed spray bars designed for maximum washing effect with minimal pump horsepower | Beneficio operativo: Provides thorough material cleaning without eroding settled gold in the sluices or overloading the water circuit | Impacto del retorno de la inversión: Can reduce process water consumption by approximately 25%, lowering pumping costs and environmental footprint.

Diseño modular BoltTogether | Base técnica: Fabricated structural modules with precision alignment pins and flanged connections | Operational Benefit Enables rapid site assembly (<10 días) 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. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria para 500 Plantas TPH | Nuestro 500 Solución de planta de lavado TPH | Ventaja (% Mejora) |
| : | : | : | : |
| Disponibilidad promedio | 8590% (downtime for maintenance/blockages) | 9496% (diseño robusto & easy access) | +6% tiempo de actividad operativa |
| Recuperación de oro fino (<100 malla)| Reliant on secondary circuits; a menudo inconsistente| Engineered primary sluice capture| +12% estimated recovery rate |
| Tiempo de cambio de revestimiento| 812 horas (tripulación completa)| <4 horas (paneles modulares)| 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. ESPECIFICACIONES TÉCNICAS

Capacidad nominal: 500 toneladas por hora (alimento seco)
Tamaño de alimentación máximo: Hasta 250 mm
Requisitos de energía: ~450 kW total installed power (Main scrubber drive, motores de pantalla, zapatillas)
Requisitos de agua: Aproximadamente 3400 US GPM at 40 PSI
Especificaciones de materiales:
Tambor de fregado: 20mm mild steel shell with bolton AR400 liners
Cubiertas de pantalla: Replaceable polyurethane panels
Sluice Trays & Riffles: Abrasionresistant aluminum or stainless steel
Marco estructural: Heavywall rectangular tubing
Dimensiones físicas (aprox., modular):
Módulo depurador: L12m x W5m x H5m
Screen/Sluice Module: L15m x W6m x H4m
Conveyor Modules: Variable lengths
Rango de operación ambiental: Diseñado para una temperatura ambiente de 20 °C a +50 °C. Dust seals and covered walkways are standard.

6. ESCENARIOS DE APLICACIÓN

Operación de placer aluvial en África occidental | 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 CONSIDERACIONES COMERCIALES

Los niveles de precios de equipos están estructurados en torno a la configuración principal:

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 Preguntas frecuentes

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

¿Cuáles son los plazos de entrega típicos??
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