1. PAINPOINT DRIVEN OPENING

Are you managing the high costs and inefficiencies of primary ore crushing in your gold processing operation? The initial size reduction stage sets the tone for your entire recovery circuit, and suboptimal performance here creates cascading downstream problems. Key challenges include:

Excessive Energy Consumption: Inefficient crushing mechanisms directly translate to unsustainable power costs, a primary operational expense.
High Maintenance Downtime: Frequent breakdowns of wear components halt your entire milling line, costing thousands per hour in lost production.
Inconsistent Feed Size: Poorly controlled discharge from the primary crusher overloads and destabilizes your ball mills or hammer mills, reducing overall recovery efficiency.
High Labor & Safety Costs: Manual feeding, adjustment, and maintenance of heavy machinery increase labor overhead and expose personnel to risk.

Is your current primary crushing solution delivering the consistent throughput, predictable operating costs, and reliable uptime required for profitable gold extraction? The right foundational equipment is critical.

2. PRODUCT OVERVIEW

The modern industrial stamp mill is a purposebuilt, heavyduty primary crusher designed for the forceful liberation of gold from quartz rock and other hard ores. Engineered for rugged continuous operation, it provides the first critical step in mineral processing by reducing runofmine ore to a manageable size for secondary milling.

Operational Workflow:
1. Feed Introduction: Raw ore is fed into a robust steel mortar box via a controlled hopper or conveyor system.
2. Mechanical Percussion: A series of mechanically lifted heavy stamps (weighted rods with molybdenum steel shoes) are sequentially dropped onto the ore bed.
3. Ore Liberation: The repeated, highimpact blows fracture the rock along natural fault lines, efficiently exposing goldbearing material.
4. Slurry Discharge: Crushed material passes through a perforated screen at the mortar box discharge, mixed with water to form a slurry for transport to secondary processing (e.g., concentration tables, cyanidation feed).

Application Scope & Limitations:
Ideal For: Hard rock gold ore (quartz), pilot plants, smalltomedium scale operations requiring robust and relatively simple mechanical crushing.
Limitations: Not suitable for soft, clayrich ores that cause packing; requires consistent ore feed size; generally lower throughput per footprint compared to highvolume jaw crusher circuits.

3. CORE FEATURES

HeavyDuty Cast Mortar Box | Technical Basis: Singlepiece highchrome alloy cast iron construction | Operational Benefit: Eliminates weld failure points and resists abrasive wear exponentially longer than fabricated steel | ROI Impact: Reduces replacement frequency by up to 300%, lowering parts inventory cost and planned downtime.

Modular Stamp Assembly | Technical Basis: Individually replaceable stamp heads (shoes) and rods | Operational Benefit: Operators can replace a single worn component in under an hour without dismantling adjacent stamps | ROI Impact: Minimizes maintenance windows by over 65% compared to monolithic designs, maintaining throughput.

CamshaftDriven Lift Mechanism | Technical Basis: Precisionmachined eccentric cams provide positive mechanical lift and controlled drop | Operational Benefit: Delivers consistent impact energy per stroke independent of line voltage fluctuations; allows for adjustable stroke length | ROI Impact: Ensures uniform product size distribution (+/ 15% improvement), optimizing downstream recovery efficiency.

Integrated Water Flush System | Technical Basis: Strategically placed nozzles provide continuous slurry transport and dust suppression | Operational Benefit: Prevents screen blinding and removes crushed material efficiently; maintains a safer, dustcontrolled environment | ROI Impact: Improves operational throughput stability by preventing choke points; reduces housekeeping and air quality compliance labor.

Centralized Grease Lubrication | Technical Basis: Automated manifold delivers measured grease to all major bearing points on a timed cycle | Operational Benefit: Eliminates manual lubrication errors and extends bearing life in highshock load environments | ROI Impact: Field data shows a 40% reduction in premature bearing failures, directly cutting unscheduled downtime costs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Legacy Stamp Mills) | Modern Industrial Stamp Mill Solution | Advantage (% Improvement) |
| : | : | : | : |
| Wear Component Life (Shoes) | 80 120 operating hours | 250 400 operating hours (with chrome alloy) | +200% |
| Mean Time Between Failure (MTBF) Drive Train| ~500 hours (improper lubrication common) |> 2,000 hours (with automated lube system) | +300% |
| Throughput Consistency (Tons/Hour Variance)| +/ 25% due to manual feed & wear drift| +/ 8% via controlled feed & modular design| +68% Consistency |
| Energy Consumption per Ton Crushed| Higher due to friction losses & inefficient motors| Optimized via direct cam drive & highefficiency motors| Documented 1520% reduction |
| Safety Incident Rate (Related to Maintenance)| Elevated due to manual adjustments under tension| Reduced via guarded access points & singlestamp isolation| Significant reduction in LTI potential |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Available in 3, 5, and 10stamp configurations. Throughput ranges from 25 TPH (3stamp) up to 815 TPH (10stamp), dependent on ore hardness and feed size.
Power Requirements: Driven by a dedicated electric motor. Requirements range from 30 HP (3stamp) to 100 HP (10stamp). All models operate on standard industrial threephase power.
Material Specifications:
Mortar Box & Dies: Highchrome cast iron alloy (500+ Brinell hardness).
Stamps & Lifters: Forged alloy steel with hardened wearing surfaces.
Frame & Camshaft: Fabricated from heavyduty structural steel plate.
Physical Dimensions (10Stamp Mill): Approximate footprint of 6m L x 3m W. Total height ~4m. Weight approximately 1822 metric tons, depending on configuration.
Environmental Operating Range: Designed for outdoor installation with standard IP54 protection. Operating temperature range: 20°C to +45°C. Requires basic concrete foundation.

6. APPLICATION SCENARIOS

MidScale Hard Rock Mine, West Africa

Challenge:A remote site experienced catastrophic failures of its jaw crusher's toggle plates every six weeks due to uncrushables in the ore feed, causing weeklong shutdowns for parts importation.Solution:The mine installed two parallel 5stamp mills as the primary crushing circuit ahead of their existing ball mill.The stamp mill's camdriven mechanism simply lifted over occasional uncrushable material without damage.Results: Primary crushing availability increased from 96%. Annual maintenance parts costs reduced by an estimated $55k USD. The consistent ~1/2" discharge product improved ball mill grinding efficiency by an estimated 12%.

Historical Tailings Reprocessing Operation

Challenge:A contractor reprocessing old tailings needed a robust method to crush agglomerated slag materials containing residual gold values without investing in an expensive mobile crushing spread.Solution:A skidmounted threestamp mill was deployed onsite as the sole primary crusher.Its simple mechanical operation was easily managed by a small crew.Results: The unit processed over 25k tons of variable material over an18month campaign with only two scheduled shoe changes.Capital expenditure was60% lower than alternative systems,and project ROI was achieved within eight months based on recovered values.

7. COMMERCIAL CONSIDERATIONS

Our stamp mill solutions are offered in clear pricing tiers based on capacity:

Tier I – Standard Duty Unit ($85k$120k): Base configuration with manual grease points,fabricated steel mortar box.Ideal for intermittent or pilot plant use.

Tier II – Production Duty Unit ($130k$190k): Includes all Core Features listed above(highchrome mortar box modular stamps automated lube).Recommended for continuous operations requiring maximum uptime.Tier III – Custom Plant Integration ($200k+): Engineered systems including integrated feed conveyors slurry sumps pumps control panelsand turnkey foundation drawings.Optional features include variable speed drivesfor stroke rate adjustment remote monitoring sensorsand wearpart diagnostic kits.Service packages are available separately ranging from basic operator trainingand annual inspectionsto comprehensive multiyear partsandlabor support agreements.Financing options including equipment leasingand milestonebased project financingcan be structured through our commercial partners

8.FAQ

Q:What is the maximum recommended feed size for your stamp mills?
A.For optimal performanceand component life we recommenda maximum feed rock sizeof6 inches(150mm)in any dimension.Largerfeed can reduce throughputand accelerate wear

Q:Canyour stamp mills be integrated intoan existing carboninpulp(CIP)or gravity circuit?
A Yes.They are designed asa modularprimarycrushingstage.Thedischarge slurryis readily pipedto secondary grindingor directlyto concentration tablessimplifying integrationinto mostexistingplant layouts

Q:Whatisthe typical noise level generatedbyanoperatingstampmill?
A Sound levelsvarybutmeasureapproximately9095dBAatone meter.Enclosure kitsare availableas an optionto reduce thisfor operationsnearcommunitiesor withstrict noise ordinances

Q:Doyou offerwearpartsmade fromdifferent materialsfor varyingore types?
A Yes Whileour standardhigh chromealloyis optimalfor silicaceousgold oreswe alsooffer manganese steel shoesfor more impact resistantapplicationsanda ceramic linedmortar boxoptionfor highlyabrasive low impactores

Q:Whatisthe lead timefora productiondutystampmill?
A Standardproductiondutyunitshavea lead timeof1620weeksfromorderconfirmationCustomintegratedsystemsrequireadditionalengineeringtimewhichwillbe detailedin yourproject proposal

Q:Aretrainingandinstallation support included?
A Comprehensiveoperatortrainingandmechanicalinstallation supervisionare includedwithall TierIIandIIIpurchasesTierIunitsincludebasicoperationalmanualsonsite trainingcanbe addedas aserviceoption