1. PAINPOINT DRIVEN OPENING

Are you scaling your alluvial or eluvial gold operation and finding that your washing and recovery processes are the bottleneck? Managing a 500 TPH throughput presents distinct challenges that directly impact your bottom line. Common operational hurdles include:
Inconsistent Feed & High Clay Content: Variable material composition leads to screen blinding, reduced scrubbing efficiency, and significant downtime for manual cleaning, costing hundreds of production hours annually.
Inefficient Fines Gold Recovery: Standard sluices or jigs struggle with fine gold particles in a highvolume slurry, resulting in measurable metal losses that accumulate over thousands of tons processed.
High Water & Power Consumption: Legacy washing plants are not optimized for specific energy consumption per ton, leading to unsustainable operational costs and limiting viable deposit locations.
Rapid Wear & Maintenance Burden: Aggressive, hightonnage processing accelerates wear on scrubber drums, screen decks, and pump systems, creating unpredictable maintenance cycles and spare parts costs.
Limited Scalability & Mobility: Fixed plant designs cannot adapt to shifting pit faces or new site locations without major capital expenditure and commissioning delays.

Is your current setup causing you to lose gold to tailings or constraining your expansion plans? The solution requires a system engineered not just for volume, but for optimal recovery and operational cost control at an industrial 500 TPH scale.

2. PRODUCT OVERVIEW

The Industrial 500 TPH Gold Mining Washing Plant is a complete, modular processing system designed for the primary washing, scrubbing, screening, and gravity concentration of goldbearing alluvial or hard rock feed material. It transforms raw, unclassified ore into concentrated heavy mineral product for final extraction.

Operational Workflow:
1. Primary Feed & Scrubbing: Runofmine (ROM) material is fed into a robust trommel scrubber or rotary scrubber, where it is aggressively cleaned and clay matrices are broken apart.
2. Sizing & Classification: The scrubbed material is screened (typically via trommel screen or vibrating screen) to separate oversize waste rock. The undersize slurry reports to the primary concentration stage.
3. Primary Gravity Concentration: Highcapacity centrifugal concentrators (e.g., Knelson or Falcon type) or optimized sluice systems capture fine and coarse gold from the screened slurry with high efficiency.
4. Tailings Management & Water Handling: Waste tailings are conveyed to a settling area or further processing, while process water is recirculated via a clarified water pond system to minimize fresh water requirements.

Application Scope & Limitations:
Scope: Ideal for alluvial/placer deposits, eluvial materials, and weathered hard rock ores where liberation occurs through washing and attrition. Suited for largescale mining operations requiring high availability.
Limitations: Not designed for primary crushing of hard rock lode deposits or chemical leaching processes. Performance is contingent on proper feed size distribution (<150mm typical) and requires a consistent water source.

3. CORE FEATURES

Modular Skid Design | Technical Basis: Preengineered structural steel skids with integrated wiring and piping | Operational Benefit: Reduces onsite installation time by up to 60%, allows for phased deployment or relocation | ROI Impact: Lower capital installation costs and future redeployment value protect investment.

HeavyDuty Trommel Scrubber | Technical Basis: Highinertia design with internal lifters and optimized water spray bars | Operational Benefit: Effectively disintegrates claybound aggregates with minimal screen blinding, ensuring consistent 500 TPH throughput | ROI Impact: Maximizes uptime by reducing stoppages for cleaning; improves overall recovery by fully liberating gold particles.

Advanced Centrifugal Concentration Circuit | Technical Basis: Multiunit array of continuousdischarge centrifugal concentrators for highvolume feed | Operational Benefit: Achieves +95% recovery rates on fine gold (100 mesh) from primary feed in a single pass | ROI Impact: Directly increases revenue by capturing gold previously lost to tailings; reduces need for secondary scavenging plants.

Intelligent Process Water Management | Technical Basis: Integrated cyclones and settling tanks with variablespeed pump drives | Operational Benefit: Recirculates up to 85% of process water; maintains optimal slurry density for concentration equipment | ROI Impact: Drastically reduces freshwater consumption and associated pumping costs; minimizes environmental footprint.

Centralized PLC Control System | Technical Basis: Programmable Logic Controller with HMI touchscreen monitoring motor loads, feed rates, and pump pressures | Operational Benefit: Enables precise control of the entire plant by a single operator; provides realtime diagnostics and fault alerts | ROI Impact: Lowers labor costs per ton processed; enables predictive maintenance to avoid catastrophic failures.

AbrasionResistant Lining Package | Technical Basis: Wear plates lined with chromium carbide or replaceable rubber modules in highimpact zones | Operational Benefit: Extends service life of critical components like scrubber drums, launders, and pump volutes in abrasive environments | ROI Impact: Reduces annual spare parts expenditure by an estimated 3040% versus standard mild steel.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (500 TPH Plant) | Our 500 TPH Washing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Fine Gold Recovery Rate (100 mesh) | 7585% (traditional sluices) | >95% (centrifugal circuit) | +1020% Recovery |
| Total Installed Power Consumption (kW) ~9001100 kW ~750850 kW 1520% Energy Use |
| Average Water Consumption (m³/hour) ~8001000 m³/hr ~600700 m³/hr 2530% Water Use |
| Planned Downtime for Wear Part Replacement (hours/month) ~4060 hours ~2436 hours 40% Maintenance Time |
| OnSite Assembly & Commissioning Time ~1216 weeks ~68 weeks 50% Installation Period |

5. TECHNICAL SPECIFICATIONS

Nominal Processing Capacity: 500 metric tons per hour (dry feed basis).
Feed Size Specification: Accepts ROM material up to 150mm; optimal performance with feed <100mm.
Power Requirements: Total connected load approximately 750850 kW. Primary supply recommended at 1000 kVA, 400/690V AC.
Water Requirements: Circuit designed for recirculation; fresh water topup typically requires 600700 m³/hour at head pressure >3 bar.
Key Material Specifications:
Scrubber Drum Shell: 20mm thick mild steel with bolton chromium carbide liners.
Structural Skids: Fabricated from highgrade S355JR steel.
Slurry Pumps: Heavyduty rubberlined or hard metal pumps with adjustable speed drives.
Physical Dimensions (Modular): Typical layout spans approx. 60m L x 25m W x 15m H. Each major skid 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 standard; noise levels comply with typical mine site regulations (<85 dB at operator stations).

6. APPLICATION SCENARIOS

LargeScale Alluvial Gold Operation in West Africa

Challenge: A major operator was experiencing severe clay blinding in their existing trommel screens at +400 TPH capacity, causing daily downtime. Furthermore, their tabling circuit was losing an estimated 15% of fine gold (<150 micron).
Solution: Implementation of our Industrial 500 TPH plant featuring an aggressive clay scrubber module followed by screening via polyurethane panels resistant to blinding. Primary recovery was handled by an array of continuous centrifugal concentrators.
Results: Screenrelated downtime was eliminated. Plant throughput consistently achieved design capacity of 500 TPH. Overall gold recovery increased by an audited +18%, paying back the capital investment in under 14 months based on incremental metal capture.

Eluvial Deposit Development in South America

Challenge: A new project required a mobile processing solution capable of following the pit face across difficult terrain while maintaining strict environmental controls on water usage due to permit limitations.
Solution: Deployment of our modular skidmounted plant configured with an enhanced closedloop water clarification system using flocculant dosing units alongside the standard modules.
Results: The plant was relocated twice within the first year using heavy haul trucks without requiring disassembly beyond module separation—recommissioning took less than one week each time.The closedloop system reduced permitted freshwater draw from a projected >800 m³/hr down to <200 m³/hr total topup requirement

Commercial Considerations

Equipment pricing is structured around core configuration packages:

1\. Base Package ($2M$2M): Includes primary feeding hopper heavyduty trommel scrubber vibrating screen basic sluice run concentrate collection system essential walkways

2\. Enhanced Recovery Package ($M$M): Upgrades Base Package replacing basic sluices with full centrifugal concentrator circuit includes necessary surge tanks distribution headers

3\. Complete Turnkey Plant ($M$M): Includes Enhanced Recovery Package plus integrated water management system PLC automation package all interconnecting conveyors electrical substation commissioning services

Optional Features:
HighG Intensity Magnetic Separator module final concentrate upgrade
Onboard diesel power generation package
Remote monitoring satellite data uplink
Spare parts starter kit

Service Packages:
Standard warranty months covering defects materials workmanship
Extended Service Plan years covering scheduled maintenance inspections priority technical support
Full Maintenance Contract fixed annual fee covering all labor parts excluding consumable wear liners

Financing Options:
Equipment leasing structures through partner financial institutions
Progress payment plans aligned manufacturing milestones
Rentalto own agreements available minimum month term

FAQ

What type deposit suitable this plant?
Designed primarily unconsolidated alluvial placer eluvial deposits where liberation occurs physical washing Effective weathered oxidized hard rock ores require minimal crushing Not suitable competent lode ore requiring extensive primary grinding

How handle variation feed grade clay content?
PLC control system allows operators adjust scrubber rotation speed water addition rates realtime maintain optimal slurry density Centrifugal concentrators feature automated concentrate flushing sequences prevent overload varying grade conditions

What typical workforce required operate plant?
Designed efficient operation central control station Single operator can manage entire process from feed discharge supported two general assistants ground inspections routine tasks Total personnel per shift typically three four individuals

Are components standardized sourcing spare parts?
Yes Critical wear components pumps motors bearings instrumentation use globally available ISO standard brands Structural fabrication adheres international design codes CAD drawings provided every part ensuring longterm supportability anywhere world

What lead time delivery commissioning?
Following order confirmation engineering lead time typically weeks Manufacturing assembly require months Shipping depends destination Final site commissioning supervised our engineers requires approximately weeks assuming site preparation complete