H1: HighCapacity Commercial Gold Ore Crushing Equipment for Maximum Plant Throughput and ROI

1. PAINPOINT DRIVEN OPENING

Are escalating operational costs and unpredictable downtime eroding your gold processing margins? The primary crushing stage is a critical bottleneck where inefficiencies cascade, impacting your entire recovery circuit. Key challenges include:

High Abrasion Costs: The extreme hardness and abrasive nature of goldquartz ores rapidly degrade crusher liners, leading to frequent, costly shutdowns for maintenance and parts replacement.
Unplanned Downtime: Mechanical failures in undersized or improperly configured crushers halt the entire processing line, costing thousands per hour in lost production.
Inconsistent Feed Size & Throughput: Fluctuations in ROM (Run of Mine) ore size can choke crushers, reducing throughput and creating inefficiencies for downstream grinding and leaching circuits.
High Energy Consumption: Inefficient crushing technology directly translates to excessive power draw per ton of ore processed, a significant and growing operational expense.
Gold Particle LockUp: Inadequate crushing can fail to properly liberate gold particles from host rock, trapping values in larger fragments and directly reducing overall recovery rates.

Is your current crushing solution equipped to handle variable ore hardness while maintaining consistent throughput and protecting your bottom line? The right commercial gold ore crushing equipment is not an expense; it is a strategic investment in plant stability and profitability.

2. PRODUCT OVERVIEW

This product line encompasses heavyduty, stationary primary jaw crushers and secondary cone crushers engineered specifically for highvolume gold ore processing. These machines form the core of your comminution circuit, designed to deliver reliable size reduction from ROM feed to a consistent product for SAG or ball mill feed.

Operational Workflow:
1. ROM ore is fed via grizzly or apron feeder into the primary jaw crusher.
2. The jaw crusher performs initial coarse reduction, typically to below 200mm.
3. Crushed material is conveyed to a scalping screen.
4. Oversize material is directed to the secondary cone crusher for further reduction.
5. Correctly sized product (e.g., 25mm) is sent to the fine ore bin or directly to grinding mills.

Application Scope: Ideal for medium to largescale hard rock gold mining operations processing quartzite, sulphideassociated ores, and other abrasive materials. Designed for continuous 24/7 operation in fixed plant installations.

Limitations: Not designed for alluvial or placer gravel operations as primary units. Maximum feed size and capacity are modeldependent; correct selection based on geotechnical survey data is essential.

3. CORE FEATURES

HeavyDuty Manganese Steel Liners | Technical Basis: Workhardening austenitic manganese steel | Operational Benefit: Liners increase in surface hardness during operation, extending service life in highly abrasive conditions by up to 30% compared to standard alloys. | ROI Impact: Reduces liner change frequency, lowering parts inventory costs and labor hours dedicated to maintenance.

Hydroset CSS Adjustment | Technical Basis: Hydraulic cylinder system for closedside setting (CSS) adjustment | Operational Benefit: Operators can adjust crusher discharge setting in under one minute without stopping the machine, allowing quick compensation for changing ore characteristics or product size requirements. | ROI Impact: Maximizes uptime; field data shows a typical saving of 12 hours per adjustment event compared to manual shim systems.

Automated Tramp Release & Clearing | Technical Basis: Hydraulic overload protection system with automatic reset | Operational Benefit: Instantaneously releases tramp steel or uncrushable material, then automatically returns the crusher to its original setting without operator intervention. | ROI Impact: Prevents catastrophic damage to major components; industry testing demonstrates a >90% reduction in downtime events caused by tramp iron.

HighStrength Forged Main Shaft | Technical Basis: Singlepiece forging from highgrade alloy steel with precise heat treatment | Operational Benefit: Provides exceptional torsional strength and fatigue resistance under cyclical loading from hard rock crushing. | ROI Impact: Eliminates shaft failure as a cause of unplanned downtime; extends major component lifecycle beyond standard industry expectations.

Labyrinth Seal & Ring Guard Protection | Technical Basis: Multistage dust seal with positivepressure grease purge system | Operational Benefit: Effectively excludes dust and fines from critical bearing compartments in dry or semidry crushing environments common in gold plants. | ROI Impact: Extends bearing service life by up to 50%, preventing one of the most common causes of premature crusher failure.

Direct Drive & VBelt Guard Options | Technical Basis: Flexible power transmission configurations with heavyduty guarding | Operational Benefit: Offers plant designers flexibility based on motor availability and site layout while ensuring operator safety with integral guarding systems compliant with global standards (ISO/CE). | ROI Impact: Simplifies installation integration; reduces project engineering time by offering adaptable solutions.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Gold Ore Crushing Solution Documented Advantage |
| : | : | : |
| Liner Life (Abrasive Quartz Ore) | ~450,000 MT crushed per set (Primary Jaw) Up to ~600,000 MT crushed per set (Primary Jaw) +33% improvement |
| Availability (Scheduled + Unscheduled) Average >92% Average >96% +4 percentage points |
| Energy Efficiency (kWh/ton crushed) Baseline Specific Power Consumption Up to 15% reduction |
| Mean Time Between Failure (MTBF) Major Components Varies by component; documented increases of 2040% over previous generation designs |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Modeldependent throughput from 350 TPH up to 2,500 TPH for primary units.
Power Requirements: Primary jaw crushers typically require 150 kW – 400 kW motors; secondary cone crushers range from 75 kW – 315 kW.
Material Specifications: Highstrength welded steel frame (ASTM A36 equivalent). Critical wear parts manufactured from premiumgrade ASTM A128 manganese steel or equivalent proprietary alloys.
Physical Dimensions (Example Primary Jaw): Feed opening up to 1600mm x 2000mm; approximate weight range from 45,000 kg – 120,000 kg depending on model.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C (4°F to +122°F). Dust sealing effective at altitudes up to 3,000 meters above sea level.

6. APPLICATION SCENARIOS

Hard Rock Underground Mine Expansion Challenge:

A West African operation scaling up production faced bottlenecks with an aging primary gyratory crusher that could not handle increased tonnage targets without excessive liner wear and vibration issues.

Solution:

Implementation of a highcapacity primary jaw crusher specifically configured for their dense quartzgold ore body as part of a new surface crushing station fed via skip from underground.

Results:

Throughput increased by 42%. Liner life improved from an average of ~320k tons crushed per set on the old unit stabilized at over ~580k tons crushed per set on the new unit within six months of operation due optimized kinematics design reducing abrasive sliding motion between liners during compression cycle

MidScale Open Pit Mine Optimization Challenge:

An Australian openpit mine experienced inconsistent feed size distribution causing frequent choking events within their secondary cone circuit leading directly into SAG mill resulting poor grind consistency ultimately affecting leach kinetics

Solution:

Installation process involved replacing two standard cone units single highperformance secondary cone equipped automated control system dynamically adjusting CSS based realtime power draw feed level sensors ensuring optimal cavity utilization

Results:

Plant achieved more stable product sizing P80 variation reduced ±15mm ±5mm This consistency contributed measurable improvement downstream grinding circuit efficiency reflected total specific energy consumption across comminution circuit decreasing approximately eight percent while maintaining same metallurgical recovery rates

7 COMMERCIAL CONSIDERATIONS

Our commercial gold ore crushing equipment is offered through flexible commercial structures designed for capital project planning:

Pricing Tiers: Based on capacity rating configuration options Standard models offer proven reliability at competitive entry points Premium configurations include advanced automation monitoring packages
Optional Features: Remote monitoring telemetry packages predictive maintenance software integration special alloy liner options specific extreme abrasion applications
Service Packages: Tiered offerings available ranging basic commissioning warranty comprehensive longterm service agreements including scheduled inspections parts supply priority technical support
Financing Options: We work established financial partners provide leasetoown structures project financing tailored match cash flow requirements new expansions brownfield upgrades

8 FAQ

1.Q What factors determine whether we need singlestage primary configuration twostage primary secondary setup?
A Selection depends primarily ROM top size required final product size total plant throughput targets Detailed analysis using Bond Work Index abrasion index data recommended our engineering team provide free circuit recommendation based your specific ore characteristics

2.Q How does this equipment integrate existing conveying screening infrastructure?
A All models designed industrystandard footprint interface points We provide detailed foundation drawings interface specifications ensure smooth integration into greenfield brownfield projects during planning phase

3.Q What typical lead time delivery commissioning support?
A Lead times vary model complexity Typically range between eighteen thirtytwo weeks exworks Commissioning performed certified field service engineers includes operator training performance verification against agreed specifications

4.Q Are spare parts readily available globally?
A We maintain regional distribution centers key mining hubs ensure critical spare parts availability Additionally provide recommended initial spare part lists based planned operating hours assist maintaining optimal inventory levels your site warehouse

5.Q Can these crushers handle ores with moderate clay content without packing?
A While primarily designed hard rock applications certain jaw models feature steeper nip angles enhanced cavity kinematics mitigate packing For operations consistently high clay content we recommend preliminary scrubbing stage prior crushing evaluate specific case detail

6.Q What warranty coverage provided?
A Standard warranty covers defects materials workmanship period twelve months commissioning date Extended warranty options major structural components main shaft frame available purchase

7.Q Do you offer performance guarantees?
A Yes we offer guaranteed capacity throughput based defined feed material characteristics formalized within contract terms Performance testing conducted during commissioning verify these guarantees