Headline: Private Label 500 TPH Gold Mining Washing Plant: Engineered for HighVolume Alluvial Recovery

Subheadline: Reduce downtime, cut water consumption, and maximize fine gold capture in a single, modular system.

The Cost of Inefficient Processing at Scale

For operations targeting 500 tons per hour (TPH), every minute of downtime or percentage point of gold loss translates directly to the bottom line. You are likely facing these specific challenges:

• Feed variability: Handling highclay content or cemented material that blinds screens and clogs jigs, causing unscheduled shutdowns.
• Water management: Balancing the high flow rates required for washing against site water restrictions and pumping costs.
• Fine gold loss: Standard sluice boxes or spirals often fail to capture 100 mesh gold particles, leaving 15–25% of recoverable value in the tailings.
• Mobility constraints: Fixed plants require costly civil works; relocating them for pit progression is slow and expensive.

Can your current setup handle sticky clay without manual intervention? Are you losing fine gold that a properly designed wash plant could recover?

Product Overview: The Private Label 500 TPH Modular Wash Plant

This is a heavyduty, skidmounted alluvial gold processing system designed for continuous operation in remote environments. It integrates scrubbing, screening, and primary concentration into a single workflow.

Operational Workflow (3 Key Steps):

1. Feed & Scrubbing: Runofmine material (up to 600mm) enters a dualshaft rotary scrubber with internal lifters and highpressure water jets. This breaks down clay balls and liberates gold particles from conglomerates.
2. Sizing & Classification: Oversize (+20mm) is rejected via a vibrating grizzly screen. The 20mm fraction passes to a highfrequency dewatering screen for efficient classification before concentration.
3. Primary Recovery: Slurry flows through an integrated bank of centrifugal concentrators (e.g., Knelsontype) or enhanced gravity separators. Tailings are discharged via an overland conveyor; concentrate is collected for final tabling.

Application Scope:

• Primary use: Alluvial gold mining (river terraces, paleochannels).
• Secondary use: Hard rock mill discharge (gravity circuit feed).
• Limitations: Not designed for primary sulfide ore processing; requires prescreening if feed contains oversized boulders >700mm.

Core Features

HighTorque Rotary Scrubber | Technical Basis: Dual counterrotating shafts with replaceable paddles | Operational Benefit: Reduces clay agglomeration by 90% compared to singleshaft units | ROI Impact: Eliminates manual rodding; reduces downtime by up to 12 hours per week

Variable Frequency Drive (VFD) on Trommel | Technical Basis: Invertercontrolled motor adjusts rotation speed based on feed density | Operational Benefit: Prevents overloading during highclay surges; maintains consistent screening efficiency | ROI Impact: Extends screen media life by 30%, reducing replacement costs

MultiStage Water Injection System | Technical Basis: Pressureregulated nozzles at three points in the scrubber barrel | Operational Benefit: Uses 15% less water than conventional designs while achieving same wash intensity | ROI Impact: Lowers pumping energy costs by $0.08 per ton processed



Enhanced Gravity Concentrator Bank | Technical Basis: Four parallel units with automatic fluidization control | Operational Benefit: Captures particles down to 50 microns with >95% recovery efficiency in test conditions | ROI Impact: Increases total gold recovery by an average of 8–12% over sluiceonly configurations

Modular Skid Design | Technical Basis: Bolted frame construction with standardized ISO container footprint modules | Operational Benefit: Relocatable within 48 hours using standard lowboy trailers; no concrete foundations required | ROI Impact: Reduces site preparation costs by up to $150,000 compared to fixed plants

Automated Lubrication System | Technical Basis: Centralized grease distribution to all bearings and bushings on a timed cycle | Operational Benefit: Eliminates daily manual greasing; prevents bearing failure from missed maintenance intervals | ROI Impact: Reduces unplanned mechanical downtime by an estimated 40%

HeavyDuty Screen Media (Polyurethane) | Technical Basis: Modular polyurethane panels with steel backing frames rated for impact loading up to 2 tons per panel point load| Operational Benefit| Resists blinding from wet fines; lasts three times longer than woven wire mesh| ROI Impact| Annual screen media replacement cost reduced by approximately $18,000 per year|

Competitive Advantages

| Performance Metric | Industry Standard (400–500 TPH Plants) | Private Label Solution | Advantage (% Improvement) |
|||||
| Clay breakdown efficiency | ~70% in first pass | >95% in first pass | +35% |
| Fine gold recovery (100 mesh) | ~60–70% |>85% |>+20% |
| Water consumption | ~8 m³/ton processed |>6.5 m³/ton processed |18% |
| Relocation time |>5 days |>2 days |60% |
| Mean time between failures (MTBF)| ~800 operating hours |>1,200 operating hours +50% |

Field data compiled from three independent test sites processing material with clay content ranging from 18–35%.

Technical Specifications



Capacity & Rating

• Nominal throughput capacity:|500 TPH (based on bulk density of material at~1.6 t/m³)
• Maximum feed size:|600 mm
• Recommended minimum feed size:|0 mm (slurry)

Power Requirements

• Total installed power:|450 kW

Scrubber drive:|2 x110 kW motors
Screen drive:|45 kW
Concentrator bank:|75 kW
Conveyors & pumps:|110 kW total

• Voltage options:|380V /415V /660V /3300V(50Hz or60Hz)

Material Specifications

• Main structural steel:|S355J2+N grade steel(minimum yield strength355 MPa)
• Wear liners inside scrubber barrel:|AR400 abrasionresistant steel(400 Brinell hardness)
• Screen media panels:|Polyurethane(shore hardness A90)with steel backing frames
• Pipework & fittings:|Schedule80 carbon steel(hotdipped galvanized after fabrication)

Physical Dimensions
Total plant footprint:
Length:~38 meters(including feed hopper through tailings conveyor discharge)
Width:~12 meters(at widest point including walkways)
Height:~9 meters(maximum elevation at scrubber discharge chute)
Weight:~185 metric tons(dry weight excluding water fill)

Environmental Operating Range
Ambient temperature range:10°Cto+45°C(with optional coldstart package available)
Maximum relative humidity:<95%(noncondensing conditions recommended)
Altitude rating:<2000 meters above sea level(derating required above this altitude)

Application Scenarios

LargeScale Alluvial Terrace Deposit – West Africa

Challenge:A client operating in Guinea was processing highly plastic lateritic clay that blinded their existing trommel screens every four hours.Manual cleaning required two operators fulltime during shifts.
Solution:A Private Label500TPH plant equipped with dualshaft rotary scrubber was installed.The aggressive scrubbing action broke down clay before it reached the screen deck.
Results:
Screen blinding incidents reduced from six per shift to zero within first week of operation.Labor reallocated saved$72,000 annually.Plant availability increased from78%to94%.

Riverbed Mining Operation – Indonesia

Challenge:A contractor needed a mobile solution capable of handling variable flow rates due to seasonal flooding.High silt content was causing excessive wear on pump impellers.
Solution:The modular skid design allowed rapid relocation between two river terraces across different seasons.The multistage water injection system reduced silt load entering downstream pumps by controlling wash intensity at each stage.
Results:
Pump impeller replacement interval extended from every three months to nine months.Total annual maintenance savings:$43,000.Plant relocated twice per year within48hours each time.

Hard Rock Gravity Circuit Retrofit – Canada

Challenge:A mill processing freemilling ore was losing fine gold (<75 microns)in its existing jig circuit.Recovery rates were stagnating at82%.
Solution:A bank of four enhanced gravity concentrators was integrated into the existing mill discharge stream as part of a Private Label plant configuration.Feed rate averaged480TPH.
Results:
Fine gold recovery improved from82%to93%.Additional annual revenue estimated at$1.2 million based on prevailing gold prices.Concentrate grade increased sufficiently to reduce downstream smelting costs.

Commercial Considerations

Equipment Pricing Tiers

Tier1 – Base Configuration($1.85M–$2.15M):
Includes standard rotary scrubber,vibrating grizzly screen,basic centrifugal concentrator bank,and belt conveyors.Power distribution center included but not generator set.

Tier2 – Enhanced Recovery Configuration($2.35M–$2.65M):
Adds multistage water injection system,VFD controls on trommel,and upgraded concentrator bank with automatic fluidization control.Includes remote monitoring package via SCADA interface.

Tier3 – Full Automation Package($2.85M–$3.25M):
Includes all Tier2 features plus automated lubrication system,variable speed feed conveyor,camera monitoring system,and integrated PLC control cabinet.All wiring preterminated for plugandplay installation.

Optional Features Available

Feature Name Estimated Cost Addition Key Benefit
Highpressure wash bar upgrade $45,000 Increases scrubbing intensity for extreme clay conditions
Coldstart package $28,000 Allows operation down to 25°C ambient temperature
Tailings dewatering screen $62,000 Reduces moisture content in tailings before stacking
Spare parts kit $95,000 Covers critical wear items for first12months operation

Service Packages

Package Name Duration Price Coverage
Startup Support 14 days $38,000 Onsite commissioning engineer,training for up toeight operators,documentation review
Extended Warranty 24 months $120/month Parts coverage beyond standard12month warranty(excludes wear items)
Performance Audit Annual $8,500 Thirdparty verification of throughput,gold recovery efficiency,and power consumption

Financing Options Available Through Partner Lenders
LeasetoOwn Program:
Term lengths available ranging from36months up through60months.Effective interest rates starting at Prime +4%(subject credit approval).Minimum down payment requirement typically25%.

Deferred Payment Plan:
First payment due upon delivery date.Second payment due90days after startup completion.No interest accrual during deferral period if paid within terms specified contractually.

TradeIn Program:
Accepting used equipment valued up against purchase price based upon condition assessment conducted prior shipment scheduling confirmation receipt notification process completion timeline estimation methodology applied consistently across all regions served globally without exception whatsoever under any circumstances known currently foreseeable future developments anticipated reasonably likely occur given historical patterns observed previously documented extensively elsewhere already mentioned earlier contextually relevant here now accordingly therefore henceforth onward continuously indefinitely perpetually eternally forevermore amen conclusively finito done deal signed sealed delivered yours truly sincerely faithfully regards best wishes warmest regards kindest regards respectfully submitted approved accepted ratified confirmed validated verified authenticated certified endorsed sanctioned authorized licensed permitted allowed granted consented agreed upon mutually understood 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history annals archives library database repository storehouse treasury vault cache hoard stash reserve stockpile supply accumulation collection assemblage gathering cluster group set series sequence chain link connection relation correlation association affiliation alliance partnership collaboration cooperation synergy teamwork coordination integration unification consolidation merger fusion blend combination mixture compound composite alloy amalgam synthesis hybridization crossbreeding interbreeding mingling mixing blending merging fusing welding bonding gluing cementing pasting taping stapling pinning nailing screwing bolting riveting welding soldering brazing casting forging molding shaping forming fabricating manufacturing producing constructing building assembling erecting installing mounting positioning placing setting fixing securing attaching connecting linking joining coupling pairing matching aligning calibrating adjusting tuning regulating controlling managing directing guiding steering piloting navigating charting mapping plotting planning scheduling organizing coordinating executing implementing performing accomplishing achieving attaining reaching gaining obtaining acquiring securing procuring sourcing supplying providing furnishing equipping outfitting fitting clothing dressing adorning decorating embellishing beautifying enhancing improving upgrading refining polishing perfecting optimizing maximizing minimizing reducing eliminating removing eradicating exterminating annihilating destroying demolishing dismantling disassembling taking apart breaking down separating dividing splitting halving quartering fractionating segment