H1: 500 Usine de lavage d'extraction d'or TPH: Conçu pour les volumes élevés, HighRecovery Operations

1. Ouverture pilotée par PainPoint

étendre la récupération de l’or alluvionnaire ou éluviale à 500 TPH presents distinct operational and financial hurdles. Inefficiencies at this scale directly erode profit margins. Êtes-vous confronté à ces défis?
Goulots d’étranglement du débit: Conventional scrubbers and sluices cannot maintain consistent feed rates, causing pileups and forcing entire plant slowdowns.
High Clay Content Disruption: Agglomerating clays blind trommel screens and matting, nécessitant de fréquents, costly manual intervention and leading to significant gold loss in the oversize fraction.
Récupération inefficace des amendes: Fine gold particles (100 engrener) are routinely lost in traditional systems, with industry estimates suggesting losses of 1530% in poorly configured plants.
Eau excessive & Demande de puissance: Outdated plant designs consume disproportionate volumes of water and power per ton processed, escalating operational costs and environmental footprint.
Temps d'arrêt imprévus: Mechanical failures in critical components like bearings, lecteurs, and pump systems halt production, costing tens of thousands per hour in lost recovery.

The central question for a plant manager is: Comment pouvez-vous obtenir un 500 TPH throughput while maximizing recovery yield and controlling operational expenses?

2. Présentation du produit

Ce 500 L'usine de lavage de TPH Gold Mining est une installation complète, modular processing system designed for the continuous scrubbing, dépistage, classification, and concentration of placer gold deposits. It is engineered to handle challenging material with high clay content and a broad particle size distribution.

Flux de travail opérationnel:
1. Lavage primaire & Dépistage: Feed material is aggressively scrubbed in a robust trommel or scrubber barrel to break down clays and conglomerates, then screened to remove oversize waste (+75mm).
2. Slurry Distribution & Classification: The undersize slurry is evenly distributed to a bank of primary concentrators (par ex., jigs or spirals) via a calibrated feed system. A hydrocyclone cluster may separate sands from slimes for targeted processing.
3. Concentration primaire: Coarse and medium gold is recovered in the primary gravity circuit.
4. Fines Recovery Enhancement: Tailings from the primary circuit are routed through specialized fine gold recovery units (par ex., concentrateurs centrifuges) to capture sub100 mesh particles.
5. Gestion des résidus & Gestion de l'eau: A dewatering screen system recovers process water for recirculation, while compacted tailings are conveyed for stacking.

Champ d'application & Limites:
Portée: Idéal pour les alluvions à grande échelle (riverine), éluvial (colluvial), and weathered deposit operations. Effective on a range of materials from sandy gravels to sticky clays.
Limites: Ne convient pas au hard rock (filon) ore processing without prior crushing. Performance is contingent on proper feed size distribution (<200mm recommended) and consistent feed rate control.

3. Fonctionnalités principales

Module d'épurateur robuste | Base technique: Système d'entraînement à couple élevé avec élévateurs internes | Avantage opérationnel: Consistently breaks apart tough clay balls and cemented gravels without clogging | Impact sur le retour sur investissement: Reduces prescreening preparation time by up to 40% and increases overall liberation efficiency.

Precision Trommel Screen | Base technique: Variablespeed drive with interchangeable screen panels | Avantage opérationnel: Allows operators to adjust retention time and change aperture size for different feed materials | Impact sur le retour sur investissement: Optimizes screening efficiency, reducing misplaced material reports by an estimated 25%.

Laminar Flow Sluice & Jig Concentration System | Base technique: Engineered riffle design with regulated water flow for optimal specific gravity separation | Avantage opérationnel: Provides high recovery rates for coarse and medium gold with minimal operator attention | Impact sur le retour sur investissement: Industry testing demonstrates consistent recovery rates above 98% pour +30 maille d'or.

Integrated Fine Gold Recovery Circuit | Base technique: Centrifugal concentration technology with automated bowl discharge | Avantage opérationnel: Captures fine gold particles (100 engrener) typically lost in conventional sluices | Impact sur le retour sur investissement: Les données de terrain montrent un 2035% increase in overall recovered ounces from previously untreatable tailings.

Système de gestion de l'eau en boucle fermée | Base technique: Highcapacity slurry pumps feeding dewatering screens into settling ponds/recirculation tanks | Avantage opérationnel: Réduit considérablement la consommation d’eau douce; ensures consistent process water supply | Impact sur le retour sur investissement: Can lower water procurement costs by up to 80%, crucial pour les sites distants.

Conception modulaire montée sur patins | Base technique: Modules préassemblés sur patins structurels robustes | Avantage opérationnel: Reduces onsite installation time by weeks, minimise les coûts des travaux de génie civil | Impact sur le retour sur investissement: Faster commissioning can accelerate revenue generation by an estimated 46 semaines.

Contrôle centralisé par API & Système de surveillance| Base technique: Contrôleur logique programmable industriel avec interface HMI surveillant les charges du moteur, taux d'avance, pressions de pompe| Avantage opérationnel:Gives operators realtime visibility into plant performance for immediate adjustment|Impact sur le retour sur investissement:Predictive maintenance alerts can reduce unplanned downtime by approximately 15%.

4. Avantages compétitifs

| Mesure de performances | Norme de l'industrie (500 Échelle TPH) | Ce 500 Solution pour usine de lavage TPH | Avantage (% Amélioration) |
|||||
| Taux global de récupération de l’or | ~8592%, often excluding fines | Réalise systématiquement >95%, inclusive of fines| +5% à +10% Récupération |
| Consommation d'eau douce | ~1500 2000 m³/jour | 6 Semaines |>200% Uptime Improvement |
| Or fin (100 Mesh) Capture Rate| Souvent 85% |>70% Amélioration |
| Installation sur site & Temps de mise en service | ~1216 Weeks |>8 Semaines |33% Temps |

5. Spécifications techniques

Capacité de conception: Débit nominal de 500 tonnes par heure (based on material density of ~1.8 t/m³).
Exigences d'alimentation: Charge totale connectée environ 850 950 kW; requires dedicated HV substation or equivalent generator array.
Spécifications matérielles:
Scrubbing Drum/Trommel Shells & Liners – Abrasionresistant steel (AR400/450)
Chutes & Launders – Hardox® steel
Concentrator Components – Polyurethane riffles / revêtements en céramique
Structural Frames – Heavywall carbon steel
Dimensions physiques (Modulaire):
Scrubber Module LxWxH approx.: ~18m x ~6m x ~7m
Primary Concentration Module LxWxH approx.: ~22m x ~8m x ~5m
Entire plant footprint typically requires ~80m x ~40m area.
Plage de fonctionnement environnementale:
Ambient Temperature Range Designed for 20°C to +50°C operation
Water Recycling System maintains efficiency up to Total Suspended Solids (TSS) <10 g/L

6. Scénarios d'application

Exploitation alluviale à grande échelle en Afrique de l’Ouest

Défi:A major operator needed to upgrade from multiple smaller plants (~200 TPH au total)to a single highcapacity unit due to expanding lease area.The challenge was managing highly abrasive,sandy clay material while recovering elusive fine gold.
Solution:A customconfigured Custom Gold Mining Washing Plant was deployed,featuring an extralong scrubber section,a dualstage screening trommel,and two stages of centrifugal concentrators specifically for fine recovery.
Résultats:The plant achieved sustained throughput of520TPH.Withina monthof commissioning,the overall site recovery rate increased from86%to96%.Water consumption dropped by75%,significantly reducing pumping costs froma distant river source.

Eluvial Deposit Processing in South America

Défi:A contractor faced severe claybinding issues that halted their existing trommel every46hoursfor manual cleaning.Finegold loss was also suspected but unquantified,causing conflict with the deposit owner over royalty payments.
Solution:The implementation focused on the heavyduty scrubbing moduleand integrated fines circuit ofthe Custom Gold Mining Washing Plant.A hydrocyclone was addedtoclassify slurry aheadof concentration.
Résultats:Theplant runsfor12hour shifts without blinding.Finegoldrecoveryaccountedforan additional22ouncesin the first week,directly verifiable through assay.Total operational availability increasedfrom65%to over92%.

7.Considérations commerciales

Les niveaux de tarification des équipements sont structurés autour de la configuration de base:

Tier1Base Configuration(Scrubber,tambour,Jigs,FinesRecovery):Priced within standard industry range fora turnkey500TPHplant.IncludesbasicPLCcontrolsandwaterrecirculationpump set.

Tier2Enhanced Configuration(Base+AutomatedFeedSystem,HydrocycloneCluster,PremiumPUlinings):Priced at apremium.Includesadvancedprocesscontrolwithdata loggingandremote monitoring capability.Optional features include mobile skidding systems,diesel power modules,and tailings thickeners.

Forfaits de services:
1.Plan de maintenance préventive:Scheduled inspectionsand parts discounts.Coverswearcomponentslike screen panels,roues de pompe,riffle mats.
2.Comprehensive Support Agreement:Coversall scheduled maintenance,includesspare parts kit,and providesoncall engineering supportwith guaranteed response times.Financing options are available through partner institutions,includingleasing structures,tailoredto project cash flow models,and potential performancelinked repayment schedules.

8.FAQ

Q:Whatis themaximumfeed size your500TPHwashingplantcanaccept?
UN:The standard design accepts amaximum lumpsizeof200mm.For largerfeed,materialsprecrushingoragrizzlyfeederis recommended asan optional upgrade.This prevents damage tothedrum internalsand ensures stable throughput.

Q:Canyourplantbe relocatedas mining facesmove?
UN:The modular skidmounted design facilitates relocation.Each major modulecan be transportedby heavy haul truck.Disconnection reconnection,and recommissioningare significantly faster than fixed plants typically requiring23weeksper move dependingon site conditions.Mobile skid options further reduce this time

Q:Whatarethecriticalspareparts we should stockonsite?
A.We provideacritical spareslistwith quotation.Key itemsinclude scrubber motor drivescreen panel sets pump wear parts(impellers liners)and asetofconcentrator riffle mats/matting.A starter kitis often includedin our service agreements

Q.How doyou quantifytheimprovementinfinegoldrecoverybefore purchase?
A.We conductbenchscale testsonyour representative bulk sampleat our facility usingtheactual components(jigs centrifuges).This providesa projected recoveryscaleup modelbasedonyour specific gradereport givingyou adata backedperformance estimate

Q.Whatisthetypicalleadtimefromorderto commissioning?
A.Forastandard configuration leadtimeis approximately2024weeks.This includesengineering fabrication shopassembly testingand shipmentExpeditedoptionsmaybe available subjectto component supply

Q.Doesyourdesignmeetinternationalsafety standards?
A.All electrical systemsare designedto IECstandards Structural designfollows recognized engineering codes(AS4100 AISC360).Comprehensive guarding emergency stop systemsand access platformsare standard Safety documentation packagesare provided