1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing a small to midscale gold operation where consistent, lowcost comminution is critical to profitability? The challenges of processing hard rock gold ore are welldocumented: excessive energy consumption from oversized equipment, high maintenance costs from abrasive materials, and the logistical complexity of operating in remote locations. These factors directly erode your margin. When your primary crushing and grinding circuit is inefficient, you face not only increased power costs but also lost recovery from inadequate liberation. Comment obtenir une fiabilité, fine grinding for effective cyanidation or gravity recovery without the capital outlay and operational overhead of a full ball mill circuit? The answer lies in a proven, purposebuilt technology: the modern Custom Stamp Mill.

2. APERÇU DU PRODUIT

UN Custom Stamp Mill is a mechanized gravitydriven crushing mill designed specifically for the liberation of freemilling gold from quartz or other host rock. It modernizes the historic stamp battery principle with durable materials and precision engineering for continuous, lowtonnage operation.

Flux de travail opérationnel:
1. Alimentation: Minerai calibré (typiquement 2" from a primary jaw crusher) is fed into a enclosed mortar box.
2. Écrasement & Affûtage: Timbres lourds levés mécaniquement (chaussures) are dropped in sequence onto the ore within the mortar box, pulverizing it by repeated impact.
3. Décharge & Classification: Pulverized material passes through a screen at the mortar box discharge, with oversize material recycled and fines reporting to subsequent gold recovery processes (par ex., écluses, concentrateurs).

Champ d'application & Limites:
Idéal pour: Minerais d'or en broyage libre, usines pilotes, smallscale commercial operations (150 DPT), historical mine reprocessing, and locations with limited water or power infrastructure.
Limites: Not suitable for refractory ores requiring fine grinding below 100 mesh for liberation, or for hightonnage operations exceeding 75 DPT. Performance is optimal on brittle, siliceous ores.

3. CARACTÉRISTIQUES PRINCIPALES

Conception de cadre modulaire | Base technique: Structure en acier à haute teneur en carbone boulonnée | Avantage opérationnel: Enables transport to remote sites in standard containers and rapid onsite assembly with minimal heavy lifting | Impact sur le retour sur investissement: Réduit le temps d'installation jusqu'à 60%, lowering total project mobilization costs

Interchangeable Stamp Shoes & Meurt | Base technique: Cast manganese steel or alloy chrome iron wear surfaces | Avantage opérationnel: Operators can reverse or replace highwear components without dismantling the stamp assembly, prolonger les intervalles d'entretien | Impact sur le retour sur investissement: Réduit d’environ les temps d’arrêt pour maintenance planifiée 30% and standardizes spare parts inventory

Hauteur de chute réglable & Cadence | Base technique: Variateur de fréquence (VFD) on camshaft motor | Avantage opérationnel: Provides precise control over impact energy and grind size to match ore hardness variability; allows softstart capability | Impact sur le retour sur investissement: Optimizes specific energy consumption (kWh/tonne) and improves overall gold recovery consistency by ensuring target liberation size

Integrated Water Injection System | Base technique: Controlled manifold with solenoid valves at each mortar box | Avantage opérationnel: Suppresses dust at point of impact and creates a slurry for efficient discharge; flow is adjustable per stamp | Impact sur le retour sur investissement: Mitigates health/safety risks and environmental dust emissions while improving material handling

Lubrification centralisée à la graisse | Base technique: Automated system servicing all major bearings on camshaft and lifters | Avantage opérationnel: Ensures critical moving parts operate under consistent lubrication pressure in dusty environments | Impact sur le retour sur investissement: Empêche la défaillance prématurée des roulements, a leading cause of unplanned downtime in abrasive applications

Système de cartouche d'écran robuste | Base technique: Quickrelease clamp mechanism on mortar box discharge | Avantage opérationnel: Allows screen mesh changes in under 15 minutes to adjust final product size for downstream process optimization | Impact sur le retour sur investissement: Increases plant operational flexibility and throughput by minimizing process changeover delays

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Petit broyeur à boulets / Broyeur à marteaux) | Custom Stamp Mill Solution | Avantage (% amélioration) |
| : | : | : | : |
| Consommation d'énergie spécifique (kWh/tonne) | 12 18 kWh/tonne (for similar grind size) | 8 10 kWh/tonne (impact gravitationnel) | ~35% de réduction |
| Coût des pièces d’usure par tonne traitée| $1.50 $3.00 (hammers/liners) | $0.75 $1.25 (stamp shoes/dies)| ~50% de réduction |
| Temps d'installation sur site| 46 semaines (fondation, alignement) | 12 semaines (assemblage modulaire) | ~70% de réduction |
| Target Grind Size (P80)| Variable; can be less efficient at coarser grinds| Optimal range of 20100 mesh for freemilling gold| More efficient within designed range|
| Noise Level at 10m| 95105 dB(UN) (constant noise) | 8590 dB(UN) (intermittent impact)| ~50% Lower Avg. Sound Pressure|

P80 = The sieve size that passes 80% of the product.

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Configurable à partir de 1 à 75 Tonnes par jour (DPT), based on number of stamps (310 units common).
Exigences d'alimentation: Primary drive motor(s): 1575 kW total (20100 HP), dependent on stamp weight and count. Standard supply: 400/480V, 3phase, 50/60 Hz.
Spécifications matérielles: Cadre: Acier au carbone ASTM A36; Timbres & Chaussures: HighChrome Cast Iron or Manganese Steel; Revêtements de boîtes de mortier: AbrasionResistant Steel Plate (>400 BHN).
Dimensions physiques: Single stamp unit footprint: ~1m x 1m; A typical 5stamp mill with feed conveyor occupies approx. L6m x W3m x H4m.
Plage de fonctionnement environnementale: Température ambiante: 20°C à +45°C; Humidity Tolerance: Jusqu'à 95% sans condensation; Designed for operation at altitudes up to 3,000m.

6. SCÉNARIOS D'APPLICATION

Mine de roche dure à petite échelle, Afrique de l'Ouest

Défi:A remote site with limited grid power required a simpletooperate grinding circuit for vein quartz ore to replace manual crushing. Diesel generation costs made highenergy milling prohibitive.
Solution:A customdesigned fivestamp mill powered by a single diesel generator was installed alongside shaking tables.
Résultats:The operation achieved a stable throughput of 8 TPD at a grind of 30 engrener. Gold recovery improved to >92%, while fuel consumption dropped by over half compared to the previously considered small ball mill option.

Historic Tailings Reprocessing Project

Défi:A contractor needed to reprocess old mill tailings containing coarse liberated gold locked in silicate fragments using a mobile plant with quick setup.
Solution:A skidmounted threestamp mill was integrated into a containerized gravity recovery plant.
Résultats:The plant was operational within five days of arrival on site.The stamp mill effectively broke apart the silicate conglomerates without overgrinding malleable gold particles.Gravity recovery rates exceeded initial estimates by over fifteen percent due to improved liberation characteristics.

7.CONSIDÉRATIONS COMMERCIALES

Niveaux de tarification:
Unité de base(3Stamp):Includes frame,cames,moteur,VFD,and one set of wear parts.
PlantReady Package(5Stamp):Includes base unit plus integrated feed conveyor,puisard,and slurry pump,motor control center(Centre multicompte).
SkidMounted/Turnkey Module:Fully assembled unit tested prior to shipment including all ancillary equipment.

Fonctionnalités facultatives:Dust enclosure kit,screen cartridge sets(assorted meshes),advanced vibration monitoring sensors,wash water recycling system.

Forfaits de services:Standard warranty covers structural integrity.Available extended service agreements include annual inspections,remises sur les pièces d'usure,and priority technical support.Financing options include equipment leasing through partner institutions tailored towards mining projects.

8.FAQ

Q:What primary crusher feed size is required for an efficient stamp mill operation?
A.For optimal performance,the feed should be reducedto minus two inches(50mm).This is typically achievedwitha small jaw crusher.A correctly sized feed prevents jammingand ensures consistentstamp drop energyis appliedto particle breakage rather than oversized rocks.

Q:Cana stamp mill handle wet or clayrich ore?
A.Stamp mills perform beston dryor moderately moist,friable ore.High clay contentcan leadto packingin themortar box reducing efficiency.In such cases,a scrubbingor classification step priorto crushingis recommended.Field data showsaddinga simple trommel screen aheadof themill can resolve this issue.

Q:Whatisthe expectedlifespanof keywear components?
A Under normal operation processing quartz ore manganese steel shoes require rotation after approximately500 hoursand replacementafter1500to2000 hoursof operation.Mortarbox dies last significantly longer.This will varybasedon specificore abrasiveness which we can evaluatefrom asample.

Q How does thenoise compareto other milling options?
A Whilethe impactcreates sound itis intermittentand often perceivedas less disruptive than constant highfrequency noisefrom hammer mills Proper installationwith basic acoustic enclosuresreadily achievescompliancewith mostsite regulations

Q Les pièces de rechange sont-elles facilement disponibles?
A Yes All wearing parts are standardizedand stockedfor immediate dispatch Critical structural componentsare fabricatedfrom common industrial steel profiles minimizing supplychain risk evenfor remote locations