H1: Maximize Recovery & Uptime with a 500 Tph Gold Mining Washing Plant

PAINPOINT DRIVEN OPENING

Are you facing escalating operational costs and unpredictable recovery rates in your highvolume alluvial or eluvial gold operation? At a 500tonperhour scale, inefficiencies translate directly into significant revenue loss. Common challenges include:
High Clay Content: Aggressive materials blind screens and clog scrubbers, causing frequent downtime for manual cleaning and reducing effective processing hours.
Variable Feed Grade: Inconsistent ore leads to gold losses in tailings, with traditional plants struggling to adapt without manual intervention.
Water & Power Intensity: Highcapacity washing demands substantial resources; inefficient designs inflate operating costs and limit viable site locations.
Maintenance Complexity: Modular plants with poor component access require extended shutdowns for routine service, impacting annual throughput targets.
Fine Gold Losses: Inadequate scrubbing and screening liberation, followed by insufficient retention time in sluicing, result in unrecoverable fine gold reporting to tails.

Is your current setup equipped to handle abrasive, highclay feed while maintaining 90%+ availability? Can you accurately track and improve recovery rates without constant sampling? The scalability of your operation depends on a washing plant engineered for these specific challenges.

PRODUCT OVERVIEW

The 500 Tph Gold Mining Washing Plant is a modular, heavyduty processing system designed for the primary washing, scrubbing, screening, and initial gravity concentration of goldbearing alluvial or hard rock saprolite material. It transforms raw, claybound ore into classified gravels and concentrated sands for downstream gold recovery (e.g., centrifugal concentrators, sluices).

Operational Workflow:
1. Primary Feed & Scrubbing: Runofmine feed is introduced into a robust hopper and conveyed to a largediameter rotary scrubber. This unit aggressively breaks down clay agglomerates and liberates gold particles from the ore matrix.
2. Primary Screening & Waste Removal: Scrubbed material discharges onto a highcapacity vibrating screen. Oversize (+75mm) barren gravels are typically rejected as waste via conveyor. Midsize material may be routed for further crushing or secondary scrubbing.
3. Secondary Screening & Classification: The screen undersize reports to a series of hydrocyclones or classifying screens to separate sands from slimes. This step is critical for removing fine clays that hinder gravity concentration.
4. Primary Gravity Concentration: The cleaned, classified sand fraction is fed onto primary recovery units such as stepped sluices or jigs to produce a primary heavy mineral concentrate.
5. Tailings Management & Water Handling: Slimes and process water are directed to a compact thickener for water recovery and clarification, reducing fresh water demand by up to 80%.

Application Scope & Limitations:
Ideal For: Largescale alluvial deposits, eluvial (weathered) gold projects, and construction aggregate operations requiring intensive material washing.
Limitations: Not a standalone solution for primary hard rock (lode) mining. Final gold extraction requires secondary concentration (e.g., centrifugal concentrators) of the primary concentrate produced by this plant.

CORE FEATURES

HeavyDuty Rotary Scrubber | Technical Basis: Hightorque drive system with internal lifters | Operational Benefit: Effectively disintegrates tough clay nodules and cemented gravels with minimal liner wear | ROI Impact: Reduces prescreening bottlenecks and increases overall gold liberation yield by targeting previously lost nuggets locked in clay balls.

Modular "PlugandProcess" Design | Technical Basis: Bolttogether skidmounted modules with integrated walkways | Operational Benefit: Enables rapid deployment onsite with minimal civil works; simplifies future plant relocation or expansion | ROI Impact: Cuts installation time by up to 40%, allowing revenue generation weeks earlier than fixed installations.

Intelligent Water Recycling System | Technical Basis: Highcapacity thickener with flocculant dosing system | Operational Benefit: Clarifies process water for immediate reuse; drastically reduces fresh water consumption and settling pond footprint | ROI Impact: Lowers water procurement costs by over 75% and mitigates environmental permitting challenges.

Advanced Screen Deck Configuration | Technical Basis: Multistage polyurethane screen decks with integrated spray bars | Operational Benefit: Provides superior blinding resistance and precise size classification even with sticky feed material | ROI Impact: Maintains design throughput consistently, avoiding the 1520% capacity loss common in standard screen setups under difficult conditions.

Centralized Process Control (PLC) | Technical Basis: Automated control panel monitoring feed rate, water pressure, and motor loads | Operational Benefit: Allows operators to optimize performance from a single station; provides alarms for preventative maintenance triggers | ROI Impact: Improves operational consistency leading to more stable recovery rates; reduces unplanned stops by identifying mechanical issues early.

QuickAccess Maintenance Design | Technical Basis: Hinged guard panels, slideout chute sections, and centralized grease points | Operational Benefit: Cuts routine service time for screen deck changes or scrubber liner inspection by half | ROI Impact: Increases plant availability directly translating to higher annual tonnage processed.

COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (500 Tph Class) | Our 500 Tph Gold Mining Washing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Scheduled Runtime)| 8285% due to extended maintenance windows| Targeted >90% via quickaccess design & component redundancy| +68% more productive hours annually |
| Water Consumption per Ton| ~3 cubic meters/ton of feed| <0.8 cubic meters/ton with closedloop recycling| Up to 73% reduction in water cost/liability |
| Clay Disintegration Efficiency| Variable; often requires presoaking or doublepass scrubbing| Consistent >95% liberation in single pass per internal testing| Reduces rehandling energy costs & process complexity |
| Deployment Time (Site Ready)| 812 weeks for assembly & commissioning| 46 weeks with preassembled modules| ~50% faster timetoproduction |

TECHNICAL SPECIFICATIONS

Design Capacity: 500 metric tons per hour (variable based on specific gravity and clay content).
Power Requirements: Approx. 8501100 kW total connected load (dependent on configuration). Designed for HV supply (6.6kV/11kV) or stepdown transformers.
Key Material Specifications:
Scrubber Drum: Abrasionresistant steel plate (minimum AR400) with boltin replaceable liners.
Screen Decks: Modular polyurethane panels.
Chute Work & Launders: Hardox® or equivalent wear steel in highimpact zones.
Structural Frame: Heavygauge painted carbon steel or optional galvanized finish.
Physical Dimensions (Modular): Approximate footprint of main processing train is 45m L x 22m W x 12m H. Each major module is transportable within standard road freight limits.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust suppression systems are integral; noise levels comply with typical mine site regulations.

APPLICATION SCENARIOS

Alluvial Gold Operation in West Africa

Challenge A project faced highly variable clay content (1060%), causing frequent screen blinding and reducing effective capacity below 350 Tph despite nominal plant rating.
Solution Implementation of our specialized trommelscrubber module combined with highpressure spray bars ahead of screening decks within the complete washing plant package.
Results Screen efficiency maintained above target; plant achieved consistent throughput at design capacity of over >480 Tph wet feed. Annualized production increased by an estimated ~28%.

Eluvial Saprolite Project in South America

Challenge Significant fine gold losses (25% to under <5%. Reported overall project recovery improved by approximately nine percentage points based on regular grade control reconciliation.

COMMERCIAL CONSIDERATIONS

Our solutions are offered under flexible commercial models tailored for capital project planning:

1. Equipment Pricing Tiers:
• Base Package – Core washing modules including scrubberfeeder assembly,
primary screening unit,
and basic conveyors
• Optimized Package – Base plus enhanced features like PLC control,
water recycling thickener,
and premium wear liners
• Turnkey Package – Complete system engineering,
installation supervision,
commissioning support,
and operator training

2. Optional Features:
• Diesel power generation module
• Semimobile trailerized configuration
• Advanced instrumentation package including density meters
and mass flow totalization

3.Service Packages:
Available service agreements range from scheduled parts supply through full annual maintenance support including remote monitoring diagnostics

4.Financing Options:
We work alongside established partners able provide equipment leasing structures project finance solutions suitable largescale mining ventures

FAQ

Q1 Is this washing plant compatible with my existing crushing circuit or trommel?
A1 Yes it is designed as both standalone solution bolton upgrade Standard conveyor interfaces flanges allow integration most upstream downstream equipment Engineering review your specific layout recommended

Q2 What impact will this have my current operating labor requirements?
A2 The automated control centralized design typically allows one operator manage entire washing circuit from control cabin reducing personnel exposure moving parts potentially lowering labor requirements per ton processed

Q3 How does pricing compare building customdesigned wash plant locally?
A3 While initial capital outlay may appear higher than piecemeal approach total cost ownership analysis factors our standardized designs proven reliability reduced commissioning risk lower longterm maintenance costs Industry data indicates lifecycle savings can exceed over fiveyear period

Q4 What typical delivery lead time after order placement?
A4 For standard configuration lead times range between weeks depending final specification complexity Current production schedules confirmed upon order commitment

Q5 Are spare parts readily available globally?
A5 We maintain strategic inventory critical wear parts consumables across key mining regions ensuring express delivery options minimize potential downtime events

Q6 Can you provide detailed process guarantee regarding recovery performance?
A6 While final gold recovery depends multiple factors beyond washing stage we provide guaranteed performance metrics related material preparation specifically clay liberation efficiency classification accuracy based representative sample tested pilot scale prior purchase agreement

Q7 What site preparation required before delivery?
A7 We provide comprehensive foundation drawings utility connection points A level compacted pad suitable bearing capacity along access fresh water source are primary requirements Detailed civil works scope document supplied early engagement phase