1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Are you managing a small to midscale gold operation where consistent, lowcost comminution is critical to profitability? The challenges of processing hard rock gold ore are welldocumented: excessive energy consumption from oversized equipment, high maintenance costs from abrasive materials, and the logistical complexity of operating in remote locations. These factors directly erode your margin. When your primary crushing and grinding circuit is inefficient, you face not only increased power costs but also lost recovery from inadequate liberation. ¿Cómo se logra ser confiable?, fine grinding for effective cyanidation or gravity recovery without the capital outlay and operational overhead of a full ball mill circuit? The answer lies in a proven, purposebuilt technology: the modern Custom Stamp Mill.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

A Custom Stamp Mill is a mechanized gravitydriven crushing mill designed specifically for the liberation of freemilling gold from quartz or other host rock. It modernizes the historic stamp battery principle with durable materials and precision engineering for continuous, lowtonnage operation.

Flujo de trabajo operativo:
1. Alimentar: Mineral dimensionado (típicamente 2" from a primary jaw crusher) is fed into a enclosed mortar box.
2. Aplastante & Molienda: Sellos pesados ​​levantados mecánicamente (zapatos) are dropped in sequence onto the ore within the mortar box, pulverizing it by repeated impact.
3. Descargar & Clasificación: Pulverized material passes through a screen at the mortar box discharge, with oversize material recycled and fines reporting to subsequent gold recovery processes (p.ej., esclusas, concentradores).

Ámbito de aplicación & Limitaciones:
Ideal para: Molienda libre de minerales de oro, plantas piloto, smallscale commercial operations (150 TPD), historical mine reprocessing, and locations with limited water or power infrastructure.
Limitaciones: Not suitable for refractory ores requiring fine grinding below 100 mesh for liberation, or for hightonnage operations exceeding 75 TPD. Performance is optimal on brittle, siliceous ores.

3. CARACTERÍSTICAS PRINCIPALES

Diseño de marco modular | Base técnica: Estructura atornillada de acero con alto contenido de carbono | Beneficio operativo: Enables transport to remote sites in standard containers and rapid onsite assembly with minimal heavy lifting | Impacto del retorno de la inversión: Reduce el tiempo de instalación hasta en 60%, lowering total project mobilization costs

Zapatos de sello intercambiables & Muere | Base técnica: Cast manganese steel or alloy chrome iron wear surfaces | Beneficio operativo: Operators can reverse or replace highwear components without dismantling the stamp assembly, ampliar los intervalos de servicio | Impacto del retorno de la inversión: Reduce el tiempo de inactividad por mantenimiento planificado en aproximadamente 30% and standardizes spare parts inventory

Altura de caída ajustable & Cadencia | Base técnica: variador de frecuencia (VFD) on camshaft motor | Beneficio operativo: Provides precise control over impact energy and grind size to match ore hardness variability; allows softstart capability | Impacto del retorno de la inversión: Optimizes specific energy consumption (kWh/tonelada) and improves overall gold recovery consistency by ensuring target liberation size

Integrated Water Injection System | Base técnica: Controlled manifold with solenoid valves at each mortar box | Beneficio operativo: Suppresses dust at point of impact and creates a slurry for efficient discharge; flow is adjustable per stamp | Impacto del retorno de la inversión: Mitigates health/safety risks and environmental dust emissions while improving material handling

Lubricación centralizada con grasa | Base técnica: Automated system servicing all major bearings on camshaft and lifters | Beneficio operativo: Ensures critical moving parts operate under consistent lubrication pressure in dusty environments | Impacto del retorno de la inversión: Previene fallos prematuros de los rodamientos, a leading cause of unplanned downtime in abrasive applications

Sistema de cartucho de pantalla de servicio pesado | Base técnica: Quickrelease clamp mechanism on mortar box discharge | Beneficio operativo: Allows screen mesh changes in under 15 minutes to adjust final product size for downstream process optimization | Impacto del retorno de la inversión: Increases plant operational flexibility and throughput by minimizing process changeover delays

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (molino de bolas pequeño / Molino de martillos) | Custom Stamp Mill Solution | Ventaja (% mejora) |
| : | : | : | : |
| Consumo de energía específico (kWh/tonelada) | 12 18 kWh/tonelada (for similar grind size) | 8 10 kWh/tonelada (impacto impulsado por la gravedad) | ~35% de reducción |
| Costo de piezas de desgaste por tonelada procesada| $1.50 $3.00 (hammers/liners) | $0.75 $1.25 (stamp shoes/dies)| ~50% de reducción |
| Tiempo de instalación en el sitio| 46 semanas (base, alineación) | 12 semanas (modular assembly) | ~70% de reducción |
| Target Grind Size (P80)| Variable; can be less efficient at coarser grinds| Optimal range of 20100 mesh for freemilling gold| More efficient within designed range|
| Noise Level at 10m| 95105 dB(A) (constant noise) | 8590 dB(A) (intermittent impact)| ~50% Lower Avg. Sound Pressure|

P80 = The sieve size that passes 80% of the product.

5. ESPECIFICACIONES TÉCNICAS

Rango de capacidad: Configurable desde 1 a 75 Toneladas por día (TPD), based on number of stamps (310 units common).
Requisitos de energía: Primary drive motor(s): 1575 kW total (20100 caballos de fuerza), dependent on stamp weight and count. Standard supply: 400/480V, 3fase, 50/60 Hz.
Especificaciones de materiales: Marco: Acero al carbono ASTM A36; Sellos & Zapatos: Hierro fundido con alto contenido de cromo o acero al manganeso; Revestimientos de cajas de mortero: AbrasionResistant Steel Plate (>400 BHN).
Dimensiones físicas: Single stamp unit footprint: ~1m x 1m; A typical 5stamp mill with feed conveyor occupies approx. L6m x W3m x H4m.
Rango de operación ambiental: Temperatura ambiente: 20°C a +45°C; Humidity Tolerance: Arriba a 95% sin condensación; Designed for operation at altitudes up to 3,000m.

6. ESCENARIOS DE APLICACIÓN

Mina de roca dura a pequeña escala, África occidental

Desafío:A remote site with limited grid power required a simpletooperate grinding circuit for vein quartz ore to replace manual crushing. Diesel generation costs made highenergy milling prohibitive.
Solución:A customdesigned fivestamp mill powered by a single diesel generator was installed alongside shaking tables.
Resultados:The operation achieved a stable throughput of 8 TPD at a grind of 30 malla. Gold recovery improved to >92%, while fuel consumption dropped by over half compared to the previously considered small ball mill option.

Historic Tailings Reprocessing Project

Desafío:A contractor needed to reprocess old mill tailings containing coarse liberated gold locked in silicate fragments using a mobile plant with quick setup.
Solución:A skidmounted threestamp mill was integrated into a containerized gravity recovery plant.
Resultados:The plant was operational within five days of arrival on site.The stamp mill effectively broke apart the silicate conglomerates without overgrinding malleable gold particles.Gravity recovery rates exceeded initial estimates by over fifteen percent due to improved liberation characteristics.

7.CONSIDERACIONES COMERCIALES

Niveles de precios:
Unidad básica(3Stamp):Includes frame,cámaras,motor,VFD,and one set of wear parts.
PlantReady Package(5Stamp):Includes base unit plus integrated feed conveyor,sumidero,and slurry pump,motor control center(MCC).
SkidMounted/Turnkey Module:Fully assembled unit tested prior to shipment including all ancillary equipment.

Características opcionales:Dust enclosure kit,screen cartridge sets(assorted meshes),advanced vibration monitoring sensors,wash water recycling system.

Paquetes de servicios:Standard warranty covers structural integrity.Available extended service agreements include annual inspections,descuentos en piezas de desgaste,and priority technical support.Financing options include equipment leasing through partner institutions tailored towards mining projects.

8.Preguntas frecuentes

q:What primary crusher feed size is required for an efficient stamp mill operation?
A.For optimal performance,the feed should be reducedto minus two inches(50milímetros).This is typically achievedwitha small jaw crusher.A correctly sized feed prevents jammingand ensures consistentstamp drop energyis appliedto particle breakage rather than oversized rocks.

q:Cana stamp mill handle wet or clayrich ore?
A.Stamp mills perform beston dryor moderately moist,friable ore.High clay contentcan leadto packingin themortar box reducing efficiency.In such cases,a scrubbingor classification step priorto crushingis recommended.Field data showsaddinga simple trommel screen aheadof themill can resolve this issue.

q:Whatisthe expectedlifespanof keywear components?
A Under normal operation processing quartz ore manganese steel shoes require rotation after approximately500 hoursand replacementafter1500to2000 hoursof operation.Mortarbox dies last significantly longer.This will varybasedon specificore abrasiveness which we can evaluatefrom asample.

Q How does thenoise compareto other milling options?
A Whilethe impactcreates sound itis intermittentand often perceivedas less disruptive than constant highfrequency noisefrom hammer mills Proper installationwith basic acoustic enclosuresreadily achievescompliancewith mostsite regulations

P ¿Hay repuestos disponibles??
A Yes All wearing parts are standardizedand stockedfor immediate dispatch Critical structural componentsare fabricatedfrom common industrial steel profiles minimizing supplychain risk evenfor remote locations