H1: HighEfficiency, LowImpact Gold Ore Crushing Systems for Modern Mining Operations

1. PAINPOINT DRIVEN OPENING

Managing a gold processing plant requires balancing throughput with profitability and increasingly, environmental responsibility. Traditional crushing circuits often undermine these goals. Are you facing these specific challenges?

Excessive Energy Consumption: Primary and secondary crushers are among the largest power draws in your plant. Inefficient comminution directly escalates operational costs, with energy representing over 30% of total processing expenses.
Unplanned Downtime from Contamination: Tramp steel or uncrushable material entering the crushing chamber causes catastrophic damage, leading to days of lost production and expensive component replacement.
Dust and Noise Compliance Costs: Meeting stringent site and regulatory standards for particulate emissions and noise often requires costly auxiliary systems, adding complexity and capital expenditure.
SubOptimal Liberation & Recovery: Inconsistent particle size distribution from older crushing technology can compromise downstream grinding and leaching efficiency, leaving valuable micron gold locked in larger particles.

How can you achieve higher throughput with lower energy input while reducing your environmental footprint? The solution lies in purposeengineered gold ore crushing equipment.

2. PRODUCT OVERVIEW

Our solution is a range of modular, highperformance cone crushers and jaw crushers specifically configured for gold ore processing. This equipment is designed for the highabrasion, often highclay content ores typical of gold deposits.

Operational Workflow:
1. Primary Size Reduction: A heavyduty jaw crusher or gyratory crusher accepts runofmine (ROM) ore, reducing it to a nominal 150mm product.
2. Secondary Crushing: A highcapacity cone crusher further reduces the ore to a consistent 25mm feed suitable for fine grinding.
3. Process Integration: The system integrates with vibrating screens in a closed circuit to ensure optimal size distribution, with oversize material automatically recirculated.

Application Scope: Ideal for hard rock lode gold deposits (quartz veins, sulphidebearing ores). Engineered for both stationary plant installations and semimobile configurations.
Limitations: Not designed as a standalone solution for alluvial/placer deposits where scrubbing and screening are primary processes. Maximum feed size is dependent on the selected primary crusher model.

3. CORE FEATURES

Advanced Chamber Design | Technical Basis: Optimized kinematics & cavity profile | Operational Benefit: Produces a more cubical product with fewer fines and slivers, improving downstream grinding efficiency | ROI Impact: Field data shows a 58% reduction in specific energy consumption in the ball mill circuit.

Automated Setting Regulation (ASR) | Technical Basis: Hydropneumatic clamping & adjustment with realtime feedback | Operational Benefit: Maintains consistent closedside setting (CSS) without manual intervention, ensuring stable product gradation | ROI Impact: Eliminates product variability, protecting recovery rates; reduces operator labor requirements by an estimated 15 hours per week.

Tramp Metal Protection System | Technical Basis: Dualacting hydraulic cylinders with pressure relief valves | Operational Benefit: Instantaneous release and reset of the crushing chamber protects against damage from uncrushable material | ROI Impact: Prevents an average of 48 hours of unscheduled downtime annually associated with chamber clearing and major repairs.

Direct Drive & Variable Frequency Drive (VFD) | Technical Basis: Hightorque motor coupled directly to the main shaft; optional VFD control | Operational Benefit: Eliminates transmission losses from Vbelts; VFD allows soft starts and speed optimization for different ore hardness | ROI Impact: Direct drive improves mechanical efficiency by ~4%; VFD can reduce startup current draw by 60%, lowering demand charges.

Integrated Dust Suppression Manifold | Technical Basis: Labyrinth seals & targeted water spray nozzles at key transfer points | Operational Benefit: Contains dust at source without saturating the ore | ROI Impact: Reduces requirement for standalone baghouses or scrubbers, cutting auxiliary system CAPEX by up to 30%.

HighWear Component Metallurgy | Technical Basis: Austenitic manganese steel castings with patented microalloying | Operational Benefit: Mantles, concaves, and jaw plates exhibit extended service life in highly abrasive silicarich ores | ROI Impact: Industry testing demonstrates a 2035% increase in wear life over standard MN14 equivalents, reducing spare parts inventory cost.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Average) | Our Gold Ore Crushing Solution | Advantage (% Improvement) |
| : | : | : | : |
| Specific Energy Consumption (kWh/t) | 0.9 1.2 kWh/t (secondary crushing) | 0.75 0.85 kWh/t (secondary crushing)| Up to 15% reduction |
| Mean Time Between Failure (MTBF) – Major Components| ~1,800 operating hours| >2,500 operating hours| ~39% increase |
| Product Fines (10mm) Generation| Typically 1822% of output| Controlled to 1518% of output| Reduced by up to ~20% |
| Noise Emission at 10m Distance| 95100 dB(A)| <85 dB(A)| Exceeds common regulatory thresholds |
| Crusher Setting Adjustment Time| 60 90 minutes (manual)| <10 minutes (ASR system)| ~85% time savings |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: Secondary crushing capacity from 150 tph to over 2,500 tph.
Power Requirements: Motor ratings from 150 kW to 600 kW per unit. Designed for dualvoltage operation (3.3kV /6.6kV).
Material Specifications: Main frame constructed from highgrade steel plate (>350 MPa yield strength). Wear liners manufactured from proprietary T12/T14 austenitic manganese steel.
Physical Dimensions (Example Model GC450): Total installed footprint of approx. L8m x W4m x H5m.
Environmental Operating Range: Designed for ambient temperatures from 25°C to +50°C. Dust protection rating of IP65 on all critical drives and bearings.

6. APPLICATION SCENARIOS

MidTier Gold Mine, West Africa

Challenge: Frequent power fluctuations and high energy costs crippling plant profitability; excessive fines generation in crushing causing packing issues in heap leach pads.
Solution: Installation of two VFDequipped cone crushers with advanced chamber profiles for tertiary crushing duty.
Results: Power draw stabilized with peak demand reduced by 22%. Fines generation decreased by 17%, improving heap permeability. Overall circuit energy use fell by an estimated $280,000 annually.

Refurbishment Project, Nevada USA

Challenge: Aging jaw crusher causing chronic bottlenecks and excessive unplanned downtime; noise levels exceeding new permit requirements.
Solution: Replacement with a new modular jaw crusher featuring an integrated dust suppression manifold and sounddampening enclosures.
Results: Plant throughput increased by 18% at the primary stage. Noise levels measured at below the permitted 85 dB(A). Downtime incidents related to primary crushing were eliminated.

7 COMMERCIAL CONSIDERATIONS

Our gold ore crushing equipment is offered under three commercial tiers:

1. Base Equipment Package: Includes core crusher(s), drive motors, lubrication system, and basic instrumentation.
2 Optimized Plant Package: Base equipment plus integrated dust suppression,VFD starters,and automated setting regulation(ASR).This package delivers maximum operational efficiency.
3 Full Circuit Solution: Optimized package plus design engineeringfor integrationwith existing screensand conveyors,and commissioning supervision.

Service packages range from basic warranty supportto comprehensive annual maintenance agreements(AMAs)that cover scheduled inspectionswear parts replacementat preagreed ratesand priority technical support.

Financing options include capital purchasedirect leasetoown agreementsand throughputbased availability contracts where payments are partially linkedto operational tonnage.

8 FAQ

Q What isthe lead timefor deliveryof acustomconfiguredgoldorecrushing unit?
A For standard modelslead timesare typically2024 weeksfrom orderconfirmation.For fully customizedcircuitsengineeringand fabricationmay extendthis periodwhich we outlinein projectspecific proposals.

Q How doesyourequipmenthandlehighclayores thattendto causechamber packing?
A Our conecrusherchambersare designedwith steeper head anglesand optimal eccentric throwsto promote material discharge.VFDcontrol also allows operators totemporarilyincreasehead speedto clear sticky material minimizing manual cleaning interventions.

Q Are yourcrushers compatiblewith existingplantaverage automation(PLC/DCS)systems?
A Yes.All unitscome standardwith modern PLCcontrolcapableof communicatingvia Modbus TCP/IPor Profinetprotocolsfor seamlessintegrationinto yourcentral controlroom.

Q Whatisthe expectedwear partconsumptioncostper tonne crushed?
A Thisis highlyoredependent.For typical silicarichgold orewear costsfor our premiumlinersrange between$0 .18and $0 .35per tonnein secondarycrushingapplications.We providewear modelingas partof our presales technical review

Q Do youofferonsiteoperator training?
A Yes.Commissioningalwaysincludes comprehensivehandson trainingfor your operationsand maintenancecrewscovering safe operationroutine maintenance troubleshooting proceduresand wear partchangeout protocols

Q Whatwarrantyperiodis offered?
A We providea standard24monthwarrantyon themain frameand allmanufacturingdefects.Wear parts(mantlesconcavesjaws)are coveredunder aseparate6monthperformance warrantyagainstpremature failure due tomaterial defects

Q Can youprovideperformance guarantees?
A For definedore characteristicsfeed sizeand moisture contentwe provideguaranteeson throughputcapacityproductsize distributionand maximumpower consumptionbackedby performance test clausesin ourcontracts