1. PAINPOINT DRIVEN OPENING

Scaling gold recovery operations to 500 Tph presents distinct engineering and financial challenges. Plant managers and engineering contractors often face:
Throughput Bottlenecks: Inefficient scrubbing and screening can cap processing capacity below 500 Tph, leaving valuable material unprocessed and limiting ROI on your deposit.
High Water & Power Consumption: Traditional washing plants can require excessive water recirculation and highhorsepower drives, directly escalating operational costs and environmental footprint.
ClayBearing Material Handling: Sticky clays and agglomerates can blind screens, reduce classification efficiency, and cause significant downtime for manual cleaning.
Inconsistent Recovery Rates: Variable feed material can lead to gold losses in fines or to inadequate liberation of gold from gangue, impacting overall plant yield.
Rapid Wear & Maintenance Costs: The abrasive nature of alluvial or hard rock feed can lead to premature failure of critical components, resulting in unplanned stoppages and high parts replacement costs.

Is your operation achieving maximum payable gold recovery at a true 500tonperhour rate? Are you managing water and energy costs effectively while minimizing maintenance downtime?

2. PRODUCT OVERVIEW

A 500 Tph Gold Mining Washing Plant is a highcapacity, modular processing system designed for the primary scrubbing, screening, and gravity concentration of alluvial or eluvial deposits, or the preconcentration of hard rock mill feed. Its core function is to liberate gold particles from waste material (gangue) and efficiently separate them by size and specific gravity.

Operational Workflow:
1. Feed & Primary Scrubbing: Runofmine (ROM) material is fed into a robust scrubber (trommel or rotary) where intense agitation breaks down clays, dissolves cemented aggregates, and liberates gold.
2. Sizing & Classification: The scrubbed ore passes over vibrating screens or within the trommel itself to separate material into distinct size fractions (e.g., +10mm oversize waste, 10mm+2mm gravels, 2mm sands).
3. Gravity Concentration: The goldbearing sand fraction is routed to a series of highcapacity gravity concentrators (such as centrifugal concentrators or sluices) to recover free gold particles.
4. Tailings Management & Water Recycling: Waste streams are conveyed away, while process water is sent to a settling system for clarification and recirculation.

Application Scope & Limitations:
This plant is engineered for largescale placer operations, alluvial projects, or as a primary wash plant for certain weathered deposits. Its effectiveness is highest on freemilling gold where liberation occurs through physical scrubbing. It is not a substitute for chemical leaching (CIL/CIP) plants required for refractory ores.

3. CORE FEATURES

HighThroughput Trommel Scrubber | Technical Basis: Optimized lifters and spray bar configuration | Operational Benefit: Ensures complete breakdown of claybound aggregates within a shorter retention time | ROI Impact: Enables consistent processing of 500 Tph of challenging material without bottlenecking downstream circuits.

Modular Vibrating Screen Deck | Technical Basis: Polyurethane modular panels with tensioned wedge system | Operational Benefit: Rapid panel changeout reduces screen blinding downtime from hours to minutes | ROI Impact: Increases plant availability by an estimated 35%, directly translating to higher annual throughput.

LowPressure, HighVolume Spray System | Technical Basis: Engineered nozzle placement and pump sizing for maximum efficiency | Operational Benefit: Achieves optimal material washing with up to 30% less water consumption per ton | ROI Impact: Lowers water procurement/pumping costs and reduces the size requirement for settling ponds.

Centralized Grease Lubrication System | Technical Basis: Automated programmable system delivering grease to all critical bearings | Operational Benefit: Eliminates manual lubrication points, ensuring bearing longevity in highdust environments | ROI Impact: Reduces bearing failure rates by up to 70%, preventing costly unplanned shutdowns.

Integrated Primary Gravity Circuit | Technical Basis: Bank of highGforce centrifugal concentrators plumbed inline with sand slurry flow | Operational Benefit: Captures free gold immediately after sizing, minimizing handling losses and security risk | ROI Impact: Improvals overall recovery rates by capturing fastsettling gold that may be lost in conventional systems.

HeavyDuty Chute & Hopper Liners | Technical Basis: Abrasionresistant steel (AR400) or composite liners at all wear points | Operational Benefit: Withstands constant abrasive flow with minimal wearthrough or replacement needs | ROI Impact: Extends liner service life by 23x compared to standard plate steel, reducing parts inventory cost.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 500 Tph Plants | Our 500 Tph Gold Mining Washing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Effective Clay Disintegration Time| ~45 minute retention time required| ~3 minute retention time achieved via optimized scrubber design| Up to 25% faster processing |
| Water Consumption per Ton Processed| ~34 m³/ton average| ~2.5 m³/ton based on field data| Up to 30% reduction |
| Screen Panel ChangeOut Time (Full Deck)| Typically 68 hours with bolted systems| Less than 4 hours with tensioned modular system| Over 40% downtime reduction |
| Bearing MTBF (Mean Time Between Failures)| ~6,000 operating hours in harsh conditions| Target >10,000 hours with centralized lube system| Over 65% improvement |
| Overall Plant Availability Target (excluding feed)| ~8588% availability due to maintenance stops| Designed for >92% availability through serviceability features| >4 percentage point increase |

5. TECHNICAL SPECIFICATIONS

Nominal Capacity: Designed for continuous operation at 500 metric tons per hour (550 US tph) of 100mm feed material.
Power Requirements: Total connected load approximately 800 950 kW, dependent on conveyor lengths and pump configurations. Requires primary voltage supply (e.g., 11kV or equivalent) with stepdown transformers.
Material Specifications:
Structural Steel: ASTM A36 primed and painted.
Wear Surfaces & Liners: AR400 AbrasionResistant Steel (minimum thickness varies by location).
Screening Media: Polyurethane modular panels on primary decks; optional wire mesh on secondary decks.
Pump Casings/Impellers: Highchrome alloy cast iron for slurry pumps.
Physical Dimensions (Approximate Footprint): Varies by layout; typical modular arrangement requires ~40m L x 20m W x 15m H area excluding stockpiles.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust suppression systems are integral. Can be designed for specific seismic or highaltitude conditions.

6. APPLICATION SCENARIOS

LargeScale Alluvial Operation in West Africa

Challenge: A major operator needed consistent throughput above 480 Tph but faced persistent screen blinding from lateritic clays, causing daily downtime exceeding two hours for cleaning.
Solution: Implementation of a customdesigned trommelbased washing plant featuring an aggressive scrubber section followed by our modular vibrating screen deck with intensive spray bars.
Results: Screen blinding incidents reduced by over 90%. The plant achieved a sustained throughput of over $10 Tph consistently during wet season operation when clay content was highest.

Eluvial Gold Project in South America

Challenge: Recovering fine flour gold from highly weathered saprolitic ore required maximum scrubbing efficiency while minimizing water usage due to remote location constraints.
Solution: A twostage washing plant was deployed using an initial scrubber followed by a log washer for stubborn clays before classification into multiple gravity circuits tailored for fine gold recovery.
Results: Field data shows overall water consumption was reduced by $28\% against the project's baseline target while achieving targeted fine gold recovery rates above $95\%$ in the gravity circuit alone.

7. COMMERCIAL CONSIDERATIONS

Pricing tiers are structured around core configuration:
1. Base Plant Tier: Includes primary scrubber/screen module, basic conveyors,and structural steel supports suitablefor known,favorable deposits.Price typically quoted within range XX USD.
2 Enhanced Recovery Tier: Base plant plus integrated primary gravity concentration circuit(centrifugal concentrators),advanced control panel,and upgraded pump specifications.Price typically quoted within range XX USD.
3 Full Modular Process Plant Tier: Complete turnkey solution including feed hopperwith grizzly,tailings conveyors,sump pumps,and clarified water recycling system.Price typically quoted within range XX USD.

Optional features include diesel power generation modules,dust encapsulation cabins,and automated sampling systems.Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including guaranteed parts availability.Financing options including equipment leasingand projectbased financing structures are available subjectto credit approval

FAQ

Q1 Is this washing plant compatible with existing crushing circuits?
A Yes.The design accepts screened feed from secondary/tertiary crushers.It can also incorporatea preliminary scalping screen moduleto handle direct ROM feedfrom smallerprimary crusher product

Q2 What impact will installing this haveon my current operators?
A Your team will benefitfrom reduced manual cleaning tasksand simplified maintenance procedures.Comprehensive trainingis providedduring commissioningto ensure efficientoperation

Q3 How does the pricing structure workand what payment termsare standard?
A Pricingis fixed upon final engineering reviewwith payment structuredas milestones:A deposit upon order,milestone paymentupon major component fabrication,and balance priorto shipment.Termsare typically30%70%

Q4 What isthe typical implementation timelinefrom orderto commissioning?
A Fora standard configurationlead timeis approximately2632 weeksfrom order acceptance exworks.Deliveryand commissioning timelinesdependon site locationand preparednessbut typicallyrequire68 weeksfor erection

Q5 Can the plant handle variationsin feed gradeor hardness?
A The mechanical designaccommodates normal variationsin material characteristics.For significant changesin ore type(e.g.,from alluvialto weathered hard rock)a consultativereviewis recommendedto optimizewear liner specificationsandscrubber drive power

Q6 Are spare parts readily available?
A We maintainstrategic inventoriesof critical wear partsand offerguaranteed48hour shippingon stocked itemsfor customerswith service agreements

Q7 What aftersales supportis included?
A All purchasesinclude12month warrantyon manufacturing defectscomprehensive commissioning supportby our engineersand accesssto technical documentationRemote diagnostic supportis availablevia optional service packages