1. PAINPOINT DRIVEN OPENING

Are you facing escalating operational costs and unpredictable recovery rates in your highvolume gold mining operation? Managing a 500 TPH throughput presents distinct challenges that directly impact your bottom line. Common pain points include:

Inconsistent Recovery in Variable Feed: Fluctuations in clay content, particle size distribution, and gold particle liberation can cause significant gold losses in standard scrubber and screen setups, leading to unrecoverable revenue.
Excessive Water & Power Consumption: Traditional highcapacity washing plants often operate inefficiently, consuming millions of liters of water and substantial megawatthours annually, creating both environmental and cost burdens.
High Maintenance Downtime: Abrasive feed materials lead to rapid wear on critical components, resulting in unplanned shutdowns that halt 500 tons of production every hour they persist.
Difficulty Meeting Environmental Compliance: Managing slimes and process water for a plant of this scale is a complex operational hurdle, with potential for costly regulatory issues.

The central question for plant managers is: How can you achieve consistent, high recovery rates at a 500 TPH scale while controlling operational expenditure and minimizing downtime? The solution requires a purposeengineered system, not just scaledup components.

2. PRODUCT OVERVIEW

The Industrial 500 TPH Gold Mining Washing Plant is a complete, modular processing system designed for the primary scrubbing, classification, and concentration of alluvial or hard rock gold ores at mass scale. Its core function is to liberate gold from host material and concentrate it into a manageable stream for final recovery.

Operational Workflow:
1. Primary Feed & Scrubbing: Runofmine (ROM) material is fed into a robust trommel or scrubber barrel, where it is aggressively agitated to break down clays and cemented aggregates.
2. Classification & Sizing: The discharged material is screened into multiple fractions (e.g., oversize waste, midsize gravels for secondary concentration, and fine sands/slimes).
3. Gravity Concentration: The goldbearing midsize fraction is routed to highcapacity centrifugal concentrators (e.g., Knelson or Falcon type) to separate heavy minerals.
4. Tailings Management & Water Handling: Fine tailings (slimes) are managed through a dedicated system, with process water clarified and recirculated to minimize fresh water demand.

Application Scope & Limitations:
Ideal For: Largescale alluvial/elluvial deposits, freemilling ores where gold is liberated via scrubbing, and hightonnage contract mining operations.
Limitations: Not suitable for refractory ores requiring chemical leaching or very fine (100 micron) gold without specialized downstream circuit additions. Feed size typically limited to <200mm.

3. CORE FEATURES

HeavyDuty Scrubber Module | Technical Basis: Hightorque drive system with internal lifters | Operational Benefit: Ensures complete disintegration of claybound conglomerates and thorough ore washing. | ROI Impact: Maximizes gold liberation at the front end, reducing losses to tailings; field data shows a 515% improvement in overall recovery compared to undersized scrubbers.

MultiStage Vibrating Classification Deck | Technical Basis: Tiered screening surfaces with adjustable mesh panels | Operational Benefit: Precise separation of +10mm waste rock, 10mm2mm concentration feed, and 2mm slimes. | ROI Impact: Optimizes feed to concentrators, reduces wear on downstream equipment, and improves water handling efficiency.

HighGForce Centrifugal Concentrator Array | Technical Basis: Batch or continuous discharge centrifuges generating up to 300 G's | Operational Benefit: Captures fine gold particles down to 30 microns from the highvolume sand fraction with exceptional efficiency. | ROI Impact: Delivers a primary concentrate significantly upgraded (often >1000:1), drastically reducing the volume for final cleaning stages.

Intelligent Process Water Recirculation System | Technical Basis: Settling ponds or clarifier tanks with automated pump controls | Operational Benefit: Recycles up to 90% of process water; manages slime settling for stable operation. | ROI Impact: Cuts fresh water consumption by millions of liters per day and reduces environmental licensing complexity.

Modular BoltTogether Design | Technical Basis: Preengineered skidmounted modules with standardized connections | Operational Benefit: Enables rapid onsite assembly and future plant reconfiguration or relocation. | ROI Impact: Reduces installation time by up to 40% compared to weldedsite builds, getting your operation to revenue faster.

AbrasionResistant Liner Package | Technical Basis: Highchrome cast iron or replaceable rubber liners in highwear zones | Operational Benefit: Extends service life in critical flow areas subject to abrasive sands and gravels. | ROI Impact: Lowers spare parts consumption and extends maintenance intervals by 3050%, directly reducing operating cost per ton.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 500 TPH Plants | Our Industrial Washing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Overall Gold Recovery Rate| 8592% (variable feed) | Consistent 9397% (with optimized feed) | +5% average increase |
| Fresh Water Consumption| ~1500 m³/operating hour | <300 m³/operating hour (with recirc.)| Up to 80% reduction |
| Mean Time Between Failure (Critical Wear Parts)| ~500750 hours| 10001200 hours| +60% improvement |
| OnSite Installation & Commissioning Time| 812 weeks| 57 weeks| ~40% reduction |
| Power Efficiency (kWh per ton processed)| Varies widely; often unoptimized| Engineered drive systems reduce draw by ~15%| Up to 15% improvement |

5. TECHNICAL SPECIFICATIONS

Design Capacity: 500 metric tons per hour (dry feed basis).
Feed Size: Accepts material up to 200mm; optimal feed <150mm.
Power Requirements: Approx. 8501100 kVA total connected load, dependent on configuration (scrubber drive, concentrators, pumps).
Water Requirements: Initial fill of approx. 250 m³; makeup water typically <300 m³/hr with closedcircuit recycling.
Material Specifications:
Scrubbing Drum: Mild steel shell with AR400 liners.
Chutes & Launders: AR400 steel or HDPE.
Screening Decks: Polyurethane or rubber modular panels.
Concentrators: Stainless steel/Ceramic wear parts.
Physical Dimensions (Modular): Typical footprint of ~40m L x 20m W x 12m H; exact layout is configurable.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; dust suppression and noise enclosures available.

6. APPLICATION SCENARIOS

LargeScale Alluvial Mining Operation in West Africa

Challenge: A contract miner needed consistent throughput on a highly variable saprolitic clay ore with nuggety gold distribution. Their existing plant experienced frequent blockages and inconsistent concentration performance.
Solution: Implementation of our Industrial Washing Plant featuring an extralong scrubber module for maximum clay breakdown followed by precise screening onto two parallel banks of centrifugal concentrators.
Results: Achieved sustained throughput of 480 TPH with overall plant availability exceeding 92%. Recovery rates stabilized at 95%, yielding an estimated additional 18kg of gold recovered per month versus the prior setup.

HighVolume Eluvial Deposit Processing in Mongolia

Challenge: An operator faced severe water scarcity constraints while processing 400 TPH of gravels from an ancient river terrace.
Solution: Deployment of our plant configured with an oversized water recirculation system including deep cone thickeners for maximum water recovery.
Results: Freshwater consumption was reduced from an estimated 600 m³/hr requirement to less than 80 m³/hr makeup water (87% reduction). This allowed the project license requirements while maintaining target throughput.

7. COMMERCIAL CONSIDERATIONS

Our Industrial Washing Plants are offered under three primary tiers:

1. Standard Configuration Package ($X.XM – $X.XM): Includes core modules—feed hopper/scrubber/screen deck/concentrator array/tailings handling—for turnkey operation on standard ore types.
2 Customized Configuration Package (+15–30%): Modifications for specific ore characteristics (e.g., higher clay content requiring log washers), extreme climates (30°C arctic packages), or specific regulatory requirements.
3 Optional Features:
Automated Control & Monitoring SCADA System
Onboard power generation packages
Secondary security concentrate handling systems

Service Packages:
Commissioning & Operator Training
Annual Preventative Maintenance Plans
Guaranteed Spare Parts Availability Programs

Financing Options:
We work with international export credit agencies as well as project finance partners who understand capital equipment needs within the mining sector offering leasetopurchase structures over typical terms ranging from three years upwards depending upon project specifics

FAQ

Q1 Is this plant compatible with my existing crushing circuit?
A Yes The plant is designed as either standalone unit receiving ROM material via frontend loader or integrated into existing circuits It accepts conveyorfed material typically requiring only simple chute modifications

Q2 What kind operational staff required run this facility?
A Efficient operation requires one control room operator two field technicians performing routine checks per shift plus maintenance crew Mechanical complexity similar conventional plants same capacity but automation reduces manual intervention

Q3 How does handle particularly sticky highclay feeds?
A For extreme clays we recommend optional heavyduty paddle mixer or log washer module preceding main scrubber This additional attrition stage ensures complete breakage preventing downstream blockages compromising throughput

Q4 What typical delivery timeline from order commissioning?
A For standard configuration lead time ranges between months depending current manufacturing schedule Site preparation civil works should proceed concurrently Modular design allows commissioning within weeks after modules arrive site

Q5 Are performance guarantees provided?
A Yes We offer performance guarantees based jointly agreed upon feed characteristics covering minimum throughput capacity maximum power consumption key component wear rates These backed comprehensive test work proposal stage

Q6 Can plant relocated once current deposit exhausted?
A Absolutely Modular bolttogether construction specifically facilitates relocation Minimal cutting welding required allowing efficient dismantling transport reassembly new site significantly protecting your capital investment

Q7 What aftersales technical support available globally?
A We provide remote diagnostics via installed monitoring systems plus global network certified service engineers Additionally maintain strategic inventory critical spare parts ensure minimal downtime support