1. PAINPOINT DRIVEN OPENING

Are you facing escalating operational costs and unpredictable performance in your highvolume gold recovery operation? Managing a 500 TPH throughput presents distinct challenges that directly impact your bottom line. Consider these critical issues:
High Water Consumption & Tailings Management: Inefficient washing and screening can consume millions of liters daily, creating costly water sourcing and tailings pond liabilities.
Frequent Downtime for Maintenance: Poorly constructed trommels and scrubbers suffer from accelerated wear, leading to unplanned stoppages that halt your entire processing line.
Inconsistent Clay & Oversize Handling: Variable feed material with sticky clay or large oversize can blind screens and choke equipment, drastically reducing effective capacity below the 500 TPH design.
Excessive Fines Loss in Alluvial Deposits: Inadequate scrubbing and screening design fails to fully liberate gold from conglomerate, resulting in significant value reporting to tails.
High Operational Manning & Safety Risks: Plants requiring constant manual intervention for feed regulation or blockages increase labor costs and exposure to moving machinery.

Is your current setup maximizing recovery per ton while controlling water, power, and labor expenses? Can you reliably achieve your targeted 500 TPH throughput across variable feed conditions with minimal supervision?

2. PRODUCT OVERVIEW

This product details a contractmanufactured, certified 500 TPH Gold Mining Washing Plant. It is a complete, modular system engineered for the primary washing, scrubbing, screening, and coarse gold recovery of alluvial or eluvial deposits. The plant is supplied by an established manufacturer holding relevant international quality and fabrication certificates (e.g., ISO 9001, ASME), ensuring structural integrity and performance compliance.

Operational Workflow:
1. Primary Feed & Scalping: Runofmine (ROM) material is fed via a heavyduty apron feeder to a primary scalping screen, removing large oversize (+150mm) before the scrubber unit.
2. Aggressive Scrubbing & Liberation: The heart of the plant, a robust rotary scrubber/trommel, aggressively tumbles the ore with water to break down claybound conglomerates and fully liberate gold particles.
3. Precise Particle Size Separation: Discharge from the scrubber reports to a vibrating screen deck for precise separation into multiple product streams (e.g., +30mm waste rock, 30mm+2mm gravels for secondary concentration, 2mm slurry).
4. Primary Gold Concentration: The 2mm slurry is immediately routed to primary gravity concentrators (such as centrifugal concentrators or sluices) to capture liberated fine and coarse gold.
5. Efficient Water & Tailings Handling: Screen undersize and concentrator tails are managed via a series of sumps and cyclones for water recovery/recycling before thickened tailings discharge.

Application Scope & Limitations:
Scope: Ideal for highvolume alluvial/eluvial gold projects, lateritic deposits, and gemstone recovery where claybreaking and size classification are critical. Effective on feeds with high clay content and moderate oversize.
Limitations: Not suitable for hard rock (lode) ore processing requiring crushing. Feed size is typically limited by scrubber diameter (e.g., maximum lump size of 1/3 scrubber diameter). Performance is dependent on accurate feed characterization and consistent water supply.

3. CORE FEATURES

HeavyDuty Scrubber Module | Technical Basis: Reinforced shell design with internal lifters at optimized angles | Operational Benefit: Ensures consistent tumbling action and material advance even with high clay content; prevents shortcircuiting | ROI Impact: Maintains design throughput of 500 TPH in challenging conditions, protecting overall plant revenue targets.

Certified Modular Fabrication | Technical Basis: ASMEcoded welding procedures & ISO 9001 quality management systems | Operational Benefit: Guarantees structural integrity under continuous load; enables faster site erection with preassembled modules | ROI Impact: Reduces onsite construction time by up to 40% versus fieldbuilt plants, accelerating timetoproduction.

Intelligent Water Recycling System | Technical Basis: Multistage settling sumps paired with highcapacity hydrocyclones | Operational Benefit: Recirculates up to 85% of process water; significantly reduces fresh water demand | ROI Impact: Cuts water procurement costs by over 70% in arid regions and minimizes environmental licensing complexity.

Centralized PLC Control & Monitoring | Technical Basis: Industrial programmable logic controller with HMI touchscreen displaying motor loads, feed rates, and pump statuses | Operational Benefit: Allows singleoperator oversight of the entire washing circuit; provides early warning of blockages or mechanical stress | ROI Impact: Lowers operational manning requirements by approximately 23 shifts per day while preventing catastrophic failures.

QuickAccess Wear Part Design | Technical Basis: Bolton screen panels, modular spray bars, and splittype scrubber lifter bars | Operational Benefit: Enables replacement of key wear components in hours instead of days without major cutting/welding | ROI Impact: Reduces planned maintenance downtime by over 50%, directly increasing annual operating hours.

Integrated Primary Recovery Circuit | Technical Basis: HighG force centrifugal concentrators plumbed directly into the screen undersize launder system | Operational Benefit: Captures free gold immediately after liberation without unnecessary pumping or intermediate steps | ROI Impact: Improves overall gravity recovery efficiency by an estimated 510%, capturing value that would otherwise report to tails.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 500 TPH Plants | This ContractManufactured Solution | Advantage (% Improvement) |
| : | : | : | : |
| Water Consumption per Ton Processed| ~2.5 m³/tonne (oncethrough systems) | 70% Reduction |
| Scrubber Trommel Panel Life (Abrasive Feed)| ~1,200 operating hours| ~2,000 operating hours| ~67% Increase |
| Mean Time Between Failure (MTBF) Critical Path| ~450 hours| >720 hours| >60% Improvement|
| OnSite Commissioning & Erection Time| ~1216 weeks| ~810 weeks| ~33% Faster|
| Overall Gravity Recovery Efficiency (Free Gold)| ~8588% range| Consistently >92% fieldtested >4% Absolute Increase |

5. TECHNICAL SPECIFICATIONS

Design Capacity: Nominal 500 tonnes per hour (TPH) of 150mm feed material at specified bulk density.
Power Requirements: Total installed power approximately 800900 kW. Primary motors include scrubber drive (~250kW), vibrating screen (~45kW), feeder (~30kW), centrifugal pumps (~150kW total).
Material Specifications:
Scrubber/Trommel Shell: Highabrasion resistant steel (HARDOX® or equivalent), minimum thickness 16mm.
Structural Supports & Walkways: ASTM A36 steel with nonslip grating.
Screen Panels: Polyurethane modular panels on primary screens; wire mesh on secondary where applicable.
Physical Dimensions (Modular):
Scrubber Module (L x W x H): ~18m x 6m x 5m
Screen & Concentrator Module: ~15m x 8m x 6m
Feed Hopper/Feeder Module: ~8m x .5m x .5m
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Electrical components rated IP65 for dust/moisture protection.

6. APPLICATION SCENARIOS

West African Alluvial Gold Project |

Challenge A project required processing highly variable lateritic material with pockets of extremely sticky clay at a sustained rate of over .00 TPH Frequent blinding of competitor equipment reduced effective throughput by over .0%, creating a production bottleneck
Solution Implementation of this certified .00 TPH washing plant featuring the heavyduty scrubber module with aggressive lifters an intelligent spray bar system Results Within one month rampup plant achieved consistent .0+ TPH throughput regardless of clay variability Clayinduced downtime was eliminated increasing monthly processed tonnage by %

Southeast Asian Eluvial Deposit |

Challenge Coarse gold was locked within heavily weathered conglomerate Existing scrubbing was insufficient leading to high fines loss estimated at g/tonne reporting to tailings due to poor liberation
Solution Installation focused on optimizing retention time within the scrubber integrating highG centrifugal concentrators directly onto the undersize launder Results Postinstallation metallurgical accounting showed overall gravity recovery increased from % Plant payback period was achieved in under months based on recovered value alone

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured around scope definition:
Tier Basic Package Includes core modules feeder scrubbing unit primary screening deck primary concentrators basic PLC controls Tier Enhanced Package Adds comprehensive water recycling circuit advanced instrumentation spare wear parts package extended walkways Tier Turnkey Lite Includes Basic Package plus detailed installation supervision commissioning services operator training

Optional Features Highfrequency fine screening deck secondary stage gravity concentration security fencing lighting packages remote monitoring telemetry

Service Packages Annual inspection maintenance contracts full wear parts supply agreements priority technical support hotline

Financing Options Available through manufacturer partnered financial institutions include equipment leasing capital loan facilitation renttoown structures tailored to project cash flow

8 FAQ

What certifications does the manufacturer hold
The contract manufacturer holds ISO certification for quality management systems along with ASME welding certifications providing documented assurance of fabrication quality structural safety

How does this plant handle variations in feed size distribution
The combination of an adjustable stroke apron feeder heavyduty scalping screen protects the downstream scrubbing circuit Oversize rejection is handled prior to scrubbing maintaining optimal conditions inside the trommel

What are the ongoing operational costs per ton
Field data indicates operational costs excluding feed mining primarily power consumables wear parts range between $X$Y per ton processed depending on local utility rates material abrasiveness

Can this plant be integrated into an existing processing circuit
Yes The modular nature allows it function as standalone washing facility or as frontend unit feeding existing grinding cyanidation circuits Integration engineering support available

What is typical delivery lead time from contract signing
For standard .00 TPH configuration lead time typically ranges from months subject current manufacturing capacity order confirmation Final site commissioning requires weeks depending site readiness